Multi-Layer Extruded Uppers For Articles Of Footwear And Other Foot-Receiving Devices

ABSTRACT

Upper components for footwear include: (a) a first upper component that includes a first layer having a first material as a first filament including first plural, non-intersecting, spaced apart path segments (wherein the first filament has a width dimension of less than 3 mm wide (and in some examples, less than 2 mm wide, less than 1.5 mm wide, less than 1 mm wide, or even less than 0.75 mm wide)); and (b) a second upper component including a fabric element formed at least in part of a fusible material, wherein the fusible material of the second upper component is fused to the first material of the first upper component (e.g., in an adhesive-free manner). Additional layers of material, including additional layers including filament and/or fabric elements, e.g., of the types described above, may be included in the upper.

CROSS- REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Pat. Application No.16/380,236 filed Apr. 10, 2019, which claims priority benefits based on:(a) U.S. Provisional Pat. Application No. 62/655,519 filed Apr. 10, 2018and (b) U.S. Provisional Pat. Application No. 62/655,539 filed Apr. 10,2018, each of which entirely incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to the field of footwear and otherfoot-receiving devices. More specifically, aspects of the presentinvention pertain to uppers for articles of footwear and otherfoot-receiving devices and methods of making the uppers.

BACKGROUND

Conventional articles of athletic footwear include two primary elements,an upper and a sole structure. The upper provides a covering for thefoot that securely receives and positions the foot with respect to thesole structure. In addition, the upper may have a configuration thatprotects the foot and provides ventilation, thereby cooling the foot andremoving perspiration. The sole structure is secured to a lower surfaceof the upper and is generally positioned between the foot and anycontact surface. In addition to attenuating ground reaction forces andabsorbing energy, the sole structure may provide traction and controlpotentially harmful foot motion, such as over pronation. Generalfeatures and configurations of uppers and sole structures are discussedin greater detail below.

The upper forms a void on the interior of the footwear for receiving thefoot. The void has the general shape of the foot, and access to the voidis provided at an ankle or foot-insertion opening. Accordingly, theupper extends over the instep and toe areas of the foot, along themedial and lateral sides of the foot, and around the heel area of thefoot. A lacing system often is incorporated into the upper toselectively change the size of the ankle opening and to permit thewearer to modify certain dimensions of the upper, particularly girth, toaccommodate feet with varying proportions. In addition, the upper mayinclude a tongue that extends under the lacing system to enhance thecomfort of the footwear (e.g., to modulate pressure applied to the footby the laces), and the upper also may include a heel counter to limit orcontrol movement of the heel.

The sole structure generally incorporates multiple layers that areconventionally referred to as an “insole,” a “midsole,” and an“outsole.” The insole (which also may constitute a sock liner) is a thinmember located within the upper and adjacent the plantar (lower) surfaceof the foot to enhance footwear comfort, e.g., to wick away moisture.The midsole, which is traditionally attached to the upper along theupper’s entire length, forms the middle layer of the sole structure andserves a variety of purposes that include controlling foot motions andattenuating impact forces. The outsole forms the ground-contactingelement of footwear and usually is fashioned from a durable,wear-resistant material that includes texturing or other features toimprove traction.

TERMINOLOGY/GENERAL INFORMATION

First, some general terminology and information is provided that willassist in understanding various portions of this specification and theinvention(s) as described herein. As noted above, the present inventionrelates to the field of footwear and other foot-receiving devices.“Foot-receiving device” means any device into which a user places atleast some portion of his or her foot. In addition to all types offootwear (described below), foot-receiving devices include, but are notlimited to: bindings and other devices for securing feet in snow skis,cross country skis, water skis, snowboards, and the like; bindings,clips, or other devices for securing feet in pedals for use withbicycles, exercise equipment, and the like; bindings, clips, or otherdevices for receiving feet during play of video games or other games;and the like. “Foot-receiving devices” may include one or more“foot-covering members” (e.g., akin to footwear upper components), whichhelp position the foot with respect to other components or structures,and one or more “foot-supporting members” (e.g., akin to footwear solestructure components), which support at least some portion(s) of aplantar surface of a user’s foot. “Securing systems” may help positionand/or securely hold the user’s foot in place with respect to thefoot-covering member(s) and/or the foot-supporting member(s). “Footwear”means any type of wearing apparel for the feet, and this term includes,but is not limited to: all types of shoes, boots, sneakers, sandals,thongs, flip-flops, mules, scuffs, slippers, sport-specific shoes (suchas cross-country shoes, golf shoes, tennis shoes, baseball cleats,soccer or football cleats, ski boots, basketball shoes, cross trainingshoes, track shoes, track field event shoes (e.g., for high jump, triplejump, etc.), etc.), and the like. “Foot-supporting members” may includecomponents for and/or functioning as midsoles and/or outsoles forarticles of footwear (or components providing corresponding functions innon-footwear type foot-receiving devices).

The terms “forward” or “forward direction” as used herein, unlessotherwise noted or clear from the context, mean toward or in a directiontoward a forward-most toe area of the footwear or foot-receiving devicestructure or component. The terms “rearward” or “rearward direction” asused herein, unless otherwise noted or clear from the context, meantoward or in a direction toward a rear-most heel area of the footwear orfoot-receiving device structure or component. The terms “lateral” or“lateral side” as used herein, unless otherwise noted or clear from thecontext, mean the outside or “little toe” side of the footwear orfoot-receiving device structure or component. The terms “medial” or“medial side” as used herein, unless otherwise noted or clear from thecontext, mean the inside or “big toe” side of the footwear orfoot-receiving device structure or component.

The term “moiré effect,” as used herein, means a visual perception thatoccurs when viewing a set of lines or dots that is superimposed onanother set of lines or dots, where the sets differ in relative size,angle, or spacing. In some examples, the “moiré effect” can be seen whentwo sets of lines (e.g., path segments) of equal thickness and equalspacing are superimposed, but one set is angled (e.g., at a few degrees)with respect to the lines (e.g., path segments) of the other set. The“moiré effect” can be seen in that case as a set of thick, ill-definedbars.

BRIEF DESCRIPTION OF THE DRAWINGS

The following Detailed Description, will be better understood when readin conjunction with the accompanying drawings in which like referencenumerals refer to the same or similar elements in all of the variousviews in which that reference number appears.

FIG. 1 shows a multi-layer upper blank made from multiple layers ofextruded filaments in accordance with one example of this invention;

FIGS. 2A-2F show various features of filament paths and filament pathsegments in upper layers in accordance with some examples of thisinvention;

FIGS. 3A-3W show various layers of extruded filament, steps in making amulti-layer upper component from extruded filaments, and variousfeatures/properties of multi-layer upper components in accordance withexamples of this invention;

FIGS. 4A-4C shows various features of a filament based upper componentengaged with another upper component by an adhesive;

FIGS. 5A-5F shows various features of a filament based upper componentengaged with another upper component in an adhesive-free manner;

FIGS. 6A-6E illustrate example steps of engaging a filament based uppercomponent with another upper component;

FIGS. 7A-7C illustrate an article of footwear including a multi-layerextruded filament component in accordance with one example of thisinvention;

FIGS. 8A-8B illustrate an article of footwear including a multi-layerextruded filament component in accordance with another example of thisinvention; and

FIG. 9 illustrates a multi-layer upper blank integrally formed with astrobel member in accordance with some examples of this invention.

The reader should understand that the attached drawings are notnecessarily drawn to scale.

DETAILED DESCRIPTION

In the following description of various examples of footwear andfoot-receiving device structures and components according to the presentinvention, reference is made to the accompanying drawings, which form apart hereof, and in which are shown by way of illustration variousexample structures and environments in which aspects of the inventionmay be practiced. It is to be understood that other structures andenvironments may be utilized and that structural and functionalmodifications may be made from the specifically described structures andfunctions without departing from the scope of the present invention.

I. Detailed Description of Example Uppers or Other Foot-CoveringComponents According to this Invention

Referring to the figures and following discussion, various articles offootwear/foot-receiving devices and features thereof in accordance withaspects of the present invention are disclosed. The footwear depictedand discussed are athletic shoes (e.g., cross country, running, or trackshoes), but the concepts disclosed with respect to this footwear may beapplied to a wide range of athletic footwear styles, including, but notlimited to: walking shoes, tennis shoes, soccer shoes, football shoes,basketball shoes, running shoes, track shoes, shoes for track fieldevents (e.g., high jump, triple jump, etc.) and cross-training shoes. Inaddition, the concepts of the present invention may be applied to a widerange of non-athletic footwear, including work boots, sandals, loafers,and dress shoes, as well as to other foot-receiving devices.

Uppers for articles of footwear (or foot-covering components for otherfoot-receiving devices) in accordance with at least some examples andaspects of this invention may include: an upper component having: (a) afirst layer comprising a first filament including first plural,non-intersecting, spaced apart path segments, wherein the first filamenthas a width dimension of less than 3 mm wide (and in some examples, lessthan 2 mm wide, less than 1.5 mm wide, less than 1 mm wide, or even lessthan 0.75 mm wide); and (b) a second layer comprising a second filamentincluding second plural, non-intersecting, spaced apart path segments,wherein the second filament has a width dimension of less than 3 mm wide(and in some examples, less than 2 mm wide, less than 1.5 mm wide, lessthan 1 mm wide, or even less than 0.75 mm wide). The second layer may atleast partially overlay the first layer and may be fused to the firstlayer at locations where the second layer contacts the first layer.Additional layers of material, including additional layers of filament,e.g., of the types described above, may be included in the upper. Thefilament material in the different layers may be the same or differentfrom one another (e.g., a thermoplastic material, a thermoplasticpolyurethane material, a hydrophobic material, a water-repellingmaterial, a non-water absorbing material, etc.), and it may be extruded,e.g., formed in a solid deposition modeling process. The filamentmaterial may comprise any material as are conventionally known and usedin solid deposition modeling arts as the fusible material (e.g.,including thermoplastics such as acrylonitrile butadiene styrene (ABS),polylactic acid (PLA), high-impact polystyrene (HIPS), thermoplasticpolyurethane (TPU), aliphatic polyamides (nylon), and/or other materialsas are conventionally known and used in the solid deposition modelingarts. The term “solid deposition modeling” as used herein includesprocesses known in the art as “fused filament fabrication” and “fuseddeposition modeling.”

Upper blanks for articles of footwear (or foot-covering components forother foot-receiving devices) in accordance with at least some examplesand aspects of this invention may include: (a) a first layer comprisinga first filament formed as a first path (e.g., a first continuous path)of extruded filament, wherein the first path (e.g., the first continuouspath) of the first filament forms a first lateral rear heel portion, afirst lateral midfoot portion, a first forefoot portion, a first medialmidfoot portion, and a first medial rear heel portion of the firstlayer, and wherein the first filament has a width dimension of less than3 mm wide (and in some examples, less than 2 mm wide, less than 1.5 mmwide, less than 1 mm wide, or even less than 0.75 mm wide); and (b) asecond layer comprising a second filament formed as a second path (e.g.,a second continuous path) of extruded filament, wherein the second path(e.g., the second continuous path) of the second filament forms a secondlateral rear heel portion, a second lateral midfoot portion, a secondforefoot portion, a second medial midfoot portion, and a second medialrear heel portion, wherein the second filament has a width dimension ofless than 3 mm wide (and in some examples, less than 2 mm wide, lessthan 1.5 mm wide, less than 1 mm wide, or even less than 0.75 mm wide),and wherein the second layer is fused to the first layer at locationswhere the second layer contacts the first layer. Additional layers ofmaterial, including additional layers of filament, e.g., of the typesdescribed above, may be included in the upper blank. The filamentmaterial in the different layers may be the same or different from oneanother (e.g., as described above). The filament layers may be extruded,e.g., in a solid deposition modeling process.

Uppers for articles of footwear (or foot-covering components for otherfoot-receiving devices) in accordance with at least some examples andaspects of this invention may include: (a) a first upper component thatincludes a first layer including a first material as a first filamentincluding first plural, non-intersecting, spaced apart path segments,wherein the first filament has a width dimension of less than 3 mm wide(and in some examples, less than 2 mm wide, less than 1.5 mm wide, lessthan 1 mm wide, or even less than 0.75 mm wide); and (b) a second uppercomponent including a fabric element formed at least in part of afusible material, wherein the fusible material of the second uppercomponent is fused to the first material of the first upper component(e.g., in an adhesive-free manner). Additional layers of material,including additional layers of filament and/or additional fabricelements, e.g., of the types described above, may be included in theupper. The filament or fabric material in the different layers may bethe same or different from one another (e.g., as described above).

Methods of forming uppers for articles of footwear (or foot-coveringcomponents for other foot-receiving devices) in accordance with at leastsome examples and aspects of this invention (and/or of the typesdescribed above) may include: (a) extruding a first material to form afirst layer comprising a first extruded filament including first plural,non-intersecting, spaced apart path segments, wherein the first extrudedfilament has a width dimension of less than 3 mm wide (and in someexamples, less than 2 mm wide, less than 1.5 mm wide, less than 1 mmwide, or even less than 0.75 mm wide); and (b) extruding a secondmaterial to form a second layer comprising a second extruded filamentincluding second plural, non-intersecting, spaced apart path segments,wherein the second extruded filament has a width dimension of less than3 mm wide (and in some examples, less than 2 mm wide, less than 1.5 mmwide, less than 1 mm wide, or even less than 0.75 mm wide), and whereinthe step of extruding the second material includes fusing the secondlayer to the first layer at locations where the second layer contactsthe first layer. The second layer at least partially overlaps the firstlayer. The filament may be deposited in a solid deposition modelingprocess.

Methods of forming uppers for articles of footwear (or foot-coveringcomponents for other foot-receiving devices) in accordance with at leastsome examples and aspects of this invention (and/or of the typesdescribed above) may include: (a) extruding a first material to form afirst layer comprising a first extruded filament as a first path (e.g.,a first continuous path), wherein the first path (e.g., the firstcontinuous path) of the first extruded filament forms a first lateralrear heel portion, a first lateral midfoot portion, a first forefootportion, a first medial midfoot portion, and a first medial rear heelportion of the first layer, and wherein the first extruded filament hasa width dimension of less than 3 mm wide (and in some examples, lessthan 2 mm wide, less than 1.5 mm wide, less than 1 mm wide, or even lessthan 0.75 mm wide); and (b) extruding a second material to form a secondlayer comprising a second extruded filament as a second path (e.g., asecond continuous path), wherein the second path (e.g., the secondcontinuous path) of the second extruded filament forms a second lateralrear heel portion, a second lateral midfoot portion, a second forefootportion, a second medial midfoot portion, and a second medial rear heelportion of the second layer, wherein the second extruded filament has awidth dimension of less than 3 mm wide (and in some examples, less than2 mm wide, less than 1.5 mm wide, less than 1 mm wide, or even less than0.75 mm wide), and wherein the step of extruding the second materialincludes fusing the second layer to the first layer at locations wherethe second layer contacts the first layer. The second layer at leastpartially overlays the first layer, and these layers may be deposited ina solid deposition modeling process. More layers of extruded filamentmay be included in the upper, if desired.

Methods of forming uppers for articles of footwear (or foot-coveringcomponents for other foot-receiving devices) in accordance with at leastsome examples and aspects of this invention (and/or of the typesdescribed above) may include: (a) extruding a first material to form afirst layer comprising a first extruded filament including first plural,non-intersecting, spaced apart path segments, wherein the first extrudedfilament has a width dimension of less than 3 mm wide (and in someexamples, less than 2 mm wide, less than 1.5 mm wide, less than 1 mmwide, or even less than 0.75 mm wide), and wherein the first layercomprising the first extruded filament forms at least a portion of afirst upper component; and (b) fusing a second upper component to thefirst upper component, wherein the second upper component includes afabric element formed at least in part of a fusible material, whereinfusible material of the second upper component is fused to the firstmaterial of the first upper component, e.g., by application of heatand/or pressure, optionally in an adhesive free manner. The first uppercomponent may include multiple layers of filament material. The extrudedfilament layer(s) may be deposited in a solid deposition modelingprocess.

Methods of forming uppers for articles of footwear (or foot-coveringcomponents for other foot-receiving devices) in accordance with at leastsome examples and aspects of this invention (and/or of the typesdescribed above) may include: (a) extruding a first material to form afirst layer comprising a first extruded filament including first plural,non-intersecting, spaced apart path segments, wherein the first extrudedfilament has a width dimension of less than 3 mm wide (and in someexamples, less than 2 mm wide, less than 1.5 mm wide, less than 1 mmwide, or even less than 0.75 mm wide), and wherein the first layercomprising the first extruded filament forms at least a portion of afirst upper component; (b) covering a portion of the first layer with arelease liner (e.g., a portion of the first layer extending inwardlyfrom a peripheral edge of the first layer); (c) extruding a secondmaterial to form a second layer comprising a second extruded filamentincluding second plural, non-intersecting, spaced apart path segments,wherein the second extruded filament has a width dimension of less than3 mm wide (and in some examples, less than 2 mm wide, less than 1.5 mmwide, less than 1 mm wide, or even less than 0.75 mm wide), wherein thestep of extruding the second material includes: (i) applying a firstportion of the second layer to the release liner such that the releaseliner extends between a first portion of the first layer and the firstportion of the second layer and (ii) fusing a second portion of thesecond layer to a second portion of the first layer at locations wherethe second layer contacts the first layer (e.g., at locations away fromthe release liner), and wherein the second layer forms a portion of thefirst upper component; (d) removing the release liner from between thefirst portion of the first layer and the first portion of the secondlayer; (e) optionally, placing a portion of a second upper componentbetween the first portion of the first layer and the first portion ofthe second layer, wherein the portion of the second upper componentoptionally includes a fabric element formed at least in part of afusible material; and (f) optionally, engaging the second uppercomponent with the first upper component. In examples where the secondupper component includes a fabric element formed at least in part by afusible material, the fusible material of the second upper component maybe fused to the first material of the first upper component and/or tothe second material of the first upper component, e.g., in an adhesivefree manner. Multiple layers of filament material may be provided oneither or both sides of the release liner (and the second uppercomponent), if desired. The layers of filament material may be depositedin a solid deposition modeling process.

Two or more layers of fused filament materials in footwear uppers inaccordance with examples of this invention may provide several optionsfor designers to control properties and/or performance characteristicsof a footwear upper and/or several options for designers to controlproperties and/or performance characteristics in different regions orzones of an individual upper. Many features or properties of an uppercan be controlled or altered, including one or more of: (a) filamentsize (e.g., extruded diameter, extruded width, or extruded thickness) inone or more filament layers of an upper and/or in one or more zones orregions in a single layer of an upper; (b) filament material in one ormore filament layers of an upper and/or in one or more zones or regionsin a single layer of an upper (e.g., a filament material’s elasticity,stretchability, strength, etc.); (c) filament spacing in one or morefilament layers of an upper and/or in one or more zones or regions in asingle layer of an upper; (d) extent of filament overlap between layersof an upper (e.g., overlap in the filament width direction and/or thefilament axial direction); (e) filament ordering layer in layers of anupper; (f) the number of filament path segments in one or more filamentlayers of an upper and/or in one or more zones or regions in a singlelayer of an upper; (g) filament path direction in one or more filamentlayers of an upper and/or in one or more zones or regions in a singlelayer of an upper; etc. Fusion at the intersections of the filamentlayers provides different connections and interactions between layers ascompared to connections between strands or yarns of knitted or wovenfabric materials. In general, filaments extending in a medio-lateraldirection of the upper (e.g., from side-to-side and/or from a top edge(e.g., by the foot-receiving and/or instep opening(s)) to a bottom edge(e.g., where the upper will engage the sole) will provide enhanced“lock-down” effect on the foot (e.g., hold the foot down onto thefootwear sole more securely). Filaments arranged in a more curved and/orserpentine pattern and/or in diamond or parallelogram shapes may providedirectional stretch features (e.g., more stretch in one direction ascompared to an opposite direction). Tighter filament spacings in or morelayers and/or within an individual layer of an upper will tend toprovide decreased flexibility, decreased stretch, decreased permeability(e.g., for air, water, or other materials), and/or decreasedbreathability for that layer and/or zone (and greater filament spacingswill tend to increase these properties for that layer and/or zone).

Given the above background and general description of aspects andexamples of this invention, a more detailed description of specificexamples of uppers, upper components, upper blanks, and/or articles offootwear in accordance with at least some examples of this inventionfollows.

II. Detailed Description of Specific Example Uppers, Upper Components,Upper Blanks, and Articles of Footwear According to this Invention

FIG. 1 illustrates an upper blank 1000 for forming an upper for anarticle of footwear (or a foot-covering component for another type offoot-receiving device) in accordance with one example of this invention.The upper blank 1000 of this example is formed from multiple layers ofextruded filament. One or more of the filament layers (and optionallyeach individual layer of the filament layers) of upper blank 1000 may beextruded as a continuous path of extruded filament, although one or more(or even all) of the individual layers need not be extruded as acontinuous path in some examples of this invention. The extrudedfilament path(s) in any one or more of the layers of the upper blank1000 may extend to form one or more of (and optionally all of): alateral rear heel portion 1002 (e.g., extending along a lateral side1002 s of the ankle/foot opening 1014 of the upper blank 1000); alateral midfoot portion 1004 (e.g., adjacent a lateral side 1004 s of aninstep opening 1012 of the upper blank 1000, which may include one ormore structures to engage a shoe lace); a forefoot portion 1006 (e.g.,which bridges from a lateral side to a medial side of the upper blank1000, forward of the midfoot portions); a medial midfoot portion 1008(e.g., adjacent a medial side 1008 s of the instep opening 1012 of theupper blank 1000, which may include one or more structures to engage ashoe lace); and a medial rear heel portion 1010 (e.g., extending along amedial side 1010 s of the ankle/foot opening 1014 of the upper blank1000). The vertical dashed lines shown in FIG. 1 generally define andbreak the upper blank 1000 into three portions or regions: (a) aposterior third (containing the lateral rear heel portion 1002 and themedial rear heel portion 1010), (b) a central third (containing thelateral midfoot portion 1004 and the medial midfoot portion 1008), and(c) an anterior third (containing the forefoot portion 1006). In someexamples of this invention, the upper blank 1000 will consistessentially of, or even consist of, the multi-layer filament structure.The white space visible in FIG. 1 for this example upper blank 1000constitutes open space between filament path segments (e.g., where onecan see completely through the upper blank 1000).

Example features of individual layers of this example multi-layer upperblank 1000 now will be described in more detail in conjunction withFIGS. 2A-2F. FIGS. 2A and 2D generally show an extruded path segment 100as may be laid down by an extruder 102 during an upper formation processin accordance with some examples of this invention (e.g., in a soliddeposition modeling or a fused deposition modeling process). As shown inthese figures, an individual path segment 100 of an extruded filamentgenerally will have an axial length L that is much greater than thewidth W and/or thickness T of the individual filament path segment. Assome more specific examples, an individual filament (and/or at least oneor more path segments 100 thereof) may have an extruded width dimensionW of less than 3 mm wide, and in some examples, less than 2 mm wide,less than 1.5 mm wide, less than 1 mm wide, or even less than 0.75 mmwide. Additionally or alternatively, an individual filament (and/or atleast one or more path segments 100 thereof) may have an extrudedthickness dimension T of less than 3 mm thick, and in some examples,less than 2 mm thick, less than 1.5 mm thick, less than 1.25 mm thick,less than 1 mm thick, or less than 0.75 mm thick, or even less than 0.5mm thick. For at least some path segments 100 (and optionally all pathsegments 100 in an upper layer and/or upper blank 1000), the widthdimension W may be greater than the thickness dimension T. The pathsegment length dimension L and/or overall continuous path length may beat least 10 times greater (and in some examples, at least 20 timesgreater, at least 50 times greater, at least 75 times greater, a least100 times greater, or even at least 150 times greater) than the widthdimension W and/or the thickness dimension T of the filament/filamentpath. Also, as described above, an individual layer of an uppercomponent may include plural, non-intersecting, spaced apart pathsegments. As some more examples, as shown in the figures, an individuallayer may include at least 5 non-intersecting path segments over pathsegment lengths of at least 25 mm, and in some examples, at least 5non-intersecting path segments over path segment lengths of at least 50mm, at least 75 mm, at least 100 mm, at least 150 mm, or even more. Asadditional examples, an individual layer may include at least 10non-intersecting path segments over any of the above path segment lengthdimensions, at least 15 non-intersecting path segments over any of theabove path segment length dimensions, or even at least 20non-intersecting path segments over any of the above path segment lengthdimensions.

As shown in FIG. 2D, the material 108 for forming the filament pathsegment 100 may be forced through the nozzle 104 of the extruder 102onto a substrate 106, which may be formed of glass or other appropriatematerial. The nozzle 104 diameter may be somewhat narrower than thefinal extruded width W of the path segment 100, e.g., because the heatedfilament material 108 may tend to flatten out after being deposited as apath segment 100 (or even may be pushed downward by the extruder 102nozzle 104). In general, increasing the temperature of the material 108being extruded may cause the deposited path segment 100 to flatten outmore (and generally increase in width W and decrease in thickness T). Inone more specific example, the nozzle 104 diameter may be about 0.4 mm,although the nozzle 104 diameter may range, for example, from 0.25 mm to2.5 mm (and in some examples, from 0.3 mm to 2 mm). The surface 106 s ofthe substrate 106 may be smooth or otherwise textured, and thecharacteristics of the bottom surface 100 s of the filament path segment100 may form to and take the shape (e.g., smooth or texturedcharacteristics) of the substrate 106 surface 106 s on which it contactsand is formed.

FIG. 2B illustrates a portion of an upper blank 1000 where two layers offilament are present. First, the first filament path segment 100 isextruded (e.g., having any one or more of the filament dimensions and/orstructural features described above), and then a second filament pathsegment 200 (e.g., as a second layer of the upper/upper blank 1000) isextruded in a direction to cross or intersect the first filament pathsegment 100. The second filament path segment 200 may directly contactthe first filament path segment 100 (at contact area 202) as it is beingextruded. Heat from the material of the second filament path segment 200during the extrusion thereof (and/or another heat source) causes thesecond filament path segment 200 to fuse together with the firstfilament path segment 100 at location(s) 202 where they contact oneanother (e.g., the material of the second filament path segment 200 maypolymerize with and seamlessly join the material of the first filamentpath segment 100, and heat from the extruded second filament pathsegment 200 as it is being deposited can support this fusion feature).In this manner, the first layer of the upper blank 1000 (including thefirst filament path segment(s) 100) can be fixedly joined to the secondlayer of the upper blank 1000 (including the second filament pathsegment(s) 200) in an adhesive free manner at contact location(s) 202.

FIGS. 2C and 2E show another manner in which two (or more) layers of anupper blank 1000 may be engaged with one another. Rather than simplyintersecting (as shown in FIG. 2B), the second extruded path segment(s)200 may be extruded at locations that generally overlap (and optionallyextend in parallel) with the first extruded path segment(s) 100 over atleast a portion of their respective axial lengths L. This actionproduces an axially extending contact area 202 between path segments 200and 100. While other options are possible, after the first path segments100 are extruded, the second path segments 200 (optionally formed in asecond layer of the upper blank 1000) can be extruded at locationsoffset slightly from the extrusion path(s) of the first path segments100. As shown in FIG. 2E, when the first path segment 100 was extruded,the nozzle 104 center was located at line 120 a. Then, when the secondpath segment 200 was extruded (e.g., with a second upper blank layer),the nozzle 104 was shifted by an offset distance D to center at line 120b. This offset distance D may be any desired amount, and in someexamples of this invention, may be between 0.5 D_(N) to 0.9 D_(N), andin some examples, between 0.625 D_(N) to 0.85 D_(N), or even about 0.75D_(N), wherein D_(N) represents the nozzle 104 diameter.

The overlapping (and substantially parallel) contact area 202 of thetype shown in FIGS. 2C and 2E may extend any desired axial length Lwithout departing from the invention. In some examples, the second pathsegment(s) 200 of the second filament (or second layer) may extendparallel to and/or partially overlap with the first path segment(s) ofthe first filament (or first layer) over a path segment length 100 of atleast 25 mm, and in some examples, at least 50 mm, at least 75 mm, atleast 100 mm, at least 150 mm, or even more. The overlapping contactarea 202 may follow along curved path segment(s) as well. Additionallyor alternatively, the overall layer path of the second layer (includingthe second path segment(s) 200): (a) may extend parallel to and/orpartially overlap with the overall layer path of the first layer(including the first path segment(s) 100) over at least 10%, at least25%, at least 50%, at least 75%, at least 85%, at least 90%, or even atleast 95% of an overall path length of the second layer and/or (b) mayextend parallel to and/or partially overlap with the overall layer pathof the first layer (including the first path segment(s) 100) over atleast 10%, at least 25%, at least 50%, at least 75%, at least 85%, atleast 90%, or even at least 95% of an overall path length of the firstlayer.

In at least some examples of this aspect of the invention, the secondpath segment(s) 200 of the second filament will overlap with the firstpath segment(s) 100 of the first filament by an overlapped width WO thatis from 5% to 50% of an overall combined width WC of the second filamentand the first filament at the location(s) of overlap. See FIG. 2C. Insome examples, this overlapped width WO may be from 10% to 45% or even15% to 40% of the overall combined width WC at the location(s) ofoverlap. When the individual filament layers are formed as plural,non-intersecting, spaced part path segments, the plurality of the secondplural, non-intersecting, spaced apart path segments (e.g., pathsegments 200) of the second filament may overlap with the plurality ofthe first plural, non-intersecting, spaced apart path segments (e.g.,path segments 100) of the first filament by an overlapped width WO thatis from 5% to 50% (or from 10% to 45% or even from 15% to 40%) of anoverall combined width WC of: (a) the second plural, non-intersecting,spaced apart path segment and (b) the first plural, non-intersecting,spaced apart path segments at the overlapping path segment location(s).Additionally or alternatively, if desired, the overlapped width WO ofone or more filaments of the second path segment(s) 200 withcorresponding first path segment(s) 100 may be within 10% to 75%, within15% to 60%, or even within 25% to 50% of the width W of the second pathsegment 200 (or of the width W of the first path segment 100) at thelocation of the overlap. Thus, WO = 0.1 W to 0.75 W, or even 0.15 W to0.6 W or 0.25 W to 0.5 W, where W is the width of either path segment100 or 200.

While FIGS. 2C and 2E show two layers of overlapping path segments 100and 200, if desired, a third layer and/or additional layers may bedeposited to partially overlap the first segment 100 and/or the secondsegment 200 at or adjacent locations where the first segment 100 and thesecond segment 200 overlap. This feature is shown as layer path segments300 in dot-dash lines in FIGS. 2C and 2E. The third layer of pathsegments 300 may overlap the first layer of path segments 100 and/or thesecond layer of path segments 200 over any of the overlapping widthand/or length ranges described above. The overlapping and substantiallyparallel path segments, e.g., each of path segments 100, 200, and/or 300shown in FIGS. 2C and 2E, may have the same or different colors. In someexamples, two or more of the overlapping and substantially parallel pathsegments may have the same general color but different shades of thatcolor. These color features, if desired, can contribute to theinteresting aesthetic characteristics of the upper component.

FIG. 2F shows additional path segment and/or path layer features thatmay be provided in at least some upper blanks 1000 and/or uppers inaccordance with aspects of this invention. As mentioned above, one ormore of the filament layers of an upper or upper blank 1000 may beformed by the extruder 102 (optionally as a continuous path). Thisfilament path may form one or more of a lateral rear heel portion, alateral midfoot portion, a forefoot portion, a medial midfoot portion,and/or a medial rear heel portion of the upper, the layer, and/or theupper blank 1000. In making these portions of the upper/upper blank 1000from the thin extruded filaments, in some areas of the upper/upper blank1000, the path segments 100 of an individual layer may be extruded tolocations that are relatively close to one another, optionally extendingin parallel. As shown in FIG. 2F, in one layer, the filament may beextruded into plural, non-intersecting, spaced apart path segmentsincluding at least 3 first non-intersecting path segments (100 a-100 eshown in FIG. 2F). In this illustrated example, each non-intersectingpath segment (100 a-100 e) of the set of non-intersecting path segmentsof the individual layer is spaced apart from each directly adjacentnon-intersecting path segments in the same layer by a spacing distance(S1 to S4 in FIG. 2F) of less than 10 mm over a length dimension L of atleast 25 mm. In some examples, the spacing distance(s) S may be lessthan 8 mm, less than 6 mm, less than 5 mm, or even less than 3 mm and/orthe length dimension L may be at least 15 mm, at least 50 mm, at least75 mm, at least 100 mm, or even at least 150 mm. The path segments 100 ato 100 e widths W1 to W5, respectively, shown in FIG. 2F may have any ofthe width characteristics described above, e.g., in conjunction withFIGS. 2A and 2D. In some examples of this invention, a second layer (oreven a third or more layers) of path segments will be depositedoverlapping and/or in parallel with the segments 100 a-100 e shown inFIG. 2F, e.g., to overlap as shown in FIGS. 2C and 2E.

The spacing distances S, the width dimensions W, and/or the overlappinglength dimensions L in a given layer may be constant or changing overthe overall layer of the path segments. As some more specific examples,a filament in a layer (and optionally a continuous path of filament) mayhave a first thickness at a first region of the upper or upper blank1000 and a second thickness at a second region of the upper or upperblank 1000, wherein the first thickness differs from the secondthickness (and optionally may be within the ranges described above).Additionally or alternatively, if desired, a filament in a layer (andoptionally a continuous path of filament) may have a first diameterand/or a first width at a first region of the upper or upper blank 1000and a second diameter and/or a second width at a second region of theupper or upper blank 1000, wherein the first diameter and/or first widthdiffers from the second diameter and/or second width (and optionally maybe within the ranges described above). The different thicknesses,widths, and/or diameters of the filament within a layer may help controlthe properties of the upper and/or upper blank 1000 (e.g., strength,durability, flexibility, stretchability, breathability, support, etc.).

Various features and examples of an upper or upper blank 1000 made frommultiple layers of filament material, e.g., like that of FIG. 1 , andmethod of making them are described in more detail below in conjunctionwith FIGS. 3A-3W. FIG. 3A shows an example first layer 300 of a firstfilament (e.g., having any of the filament features and characteristicsdescribed above) formed by extruding a first material into multiple pathsegments (e.g., having any of the path and/or path segment featuresdescribed above), e.g., via a solid deposition modeling process.Optionally, this first layer 300 may be extruded as a first continuouspath. In this illustrated example, the first path of the first filament(optionally as a continuous path) forms the following portions of thefirst layer 300: (a) a first lateral rear heel portion 302 (e.g.,extending along and/or adjacent a lateral side 302 s of the ankle/footopening 314 of the first layer 300); (b) a first lateral midfoot portion304 (e.g., extending along and/or adjacent a lateral side 304 s (or aninner edge) of an instep opening 312 of the first layer 300); (c) afirst forefoot portion 306 (e.g., which bridges from a lateral side to amedial side of the first layer 300, forward of the midfoot portions);(d) a first medial midfoot portion 308 (e.g., extending along and/oradjacent a medial side 308 s (or inner edge) of the instep opening 312of the first layer 300); and (e) a first medial rear heel portion 310(e.g., extending along and/or adjacent a medial side 310 s of theankle/foot opening 314 of the first layer 300). The vertical dashedlines shown in FIG. 3A generally define and break the first layer 300into three portions: (a) a posterior third (containing the lateral rearheel portion 302 and the medial rear heel portion 310), (b) a centralthird (containing the lateral midfoot portion 304 and the medial midfootportion 308), and (c) an anterior third (containing the forefoot portion306). In at least some examples of this invention, the first layer 300will consist essentially of, or even consist of, this filament structure(optionally formed as a continuous path and/or as a one piececonstruction). The white space visible in FIG. 3A for this example firstlayer 300 constitutes open space between filament path segments (e.g.,where one can see completely through the first layer 300).

While the path segments of the first layer 300 can be extruded in anydesired order without departing from this invention, in some examples ofthis invention, the outer perimeter (e.g., 300P) may be extruded first,and then the remainder of the layer 300 can be extruded, e.g., in a“raster” like fashion, to fill in the area within the perimeter 300P. Inthis illustrated example, the extruded overall path of the first layer300 lays down the first filament over much of the overall surface areaof the first layer 300 as first plural, non-intersecting, spaced apartpath segments that extend in a substantially medio-lateral direction ofthe first layer 300. Medio-lateral oriented and/or extending filamentsof this type can help enhance the “lock down” features of the upper(e.g., help securely hold the foot down on the sole structure) and mayhelp control/decrease stretchability. Along the lateral rear heel area302 and the medial rear heel area 310, the first filament path segmentsextend generally from the ankle opening 302 s/310 s to a bottomperimeter portion 302 t/310 t of the first layer 300 (e.g., where thefirst layer 300 will meet a sole structure in a final article offootwear structure), where adjacent path segments of layer 300 extendsubstantially in parallel. Similarly, along the lateral midfoot area 304and the medial midfoot area 308, the first filament path segments extendgenerally from the instep opening 312's inner edges 304 s/308 s to abottom perimeter portion 304 t/308 t (outer edges) of the first layer300 (e.g., where the first layer 300 will meet a sole structure in afinal article of footwear structure), where adjacent path segments ofthe layer 300 extend substantially in parallel. At the forefoot region306, the first filament path segments extend generally from the lateralbottom edge 306 s to the medial bottom edge 306 t of the first layer 300(e.g., where the first layer 300 will meet a sole structure in a finalarticle of footwear structure), where adjacent path segments of layer300 extend substantially in parallel. The path segments in these variousregions 302, 304, 306, 308, 310 may have any of the features and/oroptions described above for the path segments shown in FIGS. 2A-2F.

In the first layer 300, the path segments in one area need not haveconstant spacing from directly adjacent path segments at other areas ofthe first layer 300. For example, as shown in FIG. 3A, the plural,non-intersecting, spaced apart path segments in the forefoot region 306and/or the midfoot regions 304/308 of the first layer 300 are spacedcloser together than are the plural, non-intersecting, spaced apart pathsegments in the heel region(s) 302/310 of the first layer 300. The pathsegment spacings (e.g., S1 to S4 from FIG. 2E) can be selected toprovide desired characteristics for individual regions of the layer 300,the upper, and/or the upper blank 1000 (e.g., desired stretchability,breathability, etc.).

After the first layer 300 is extruded (e.g., onto a substrate 106), asecond layer 350 of the overall upper or upper blank 1000 then may beapplied to the first layer 300. FIG. 3B shows the individual pathsegments of this example second layer 350, and FIG. 3C schematicallyshows the production of the second layer 350 onto the previouslyprepared first layer 300 to create the combined first and second layers380 of the upper or upper blank 1000. More specifically, FIG. 3B shows asecond layer 350 formed of a second filament (e.g., having any of thefilament features and characteristics described above) and formed byextruding a second material into multiple path segments (e.g., havingany of the path and/or path segment features described above), e.g., viaa solid deposition modeling process. Optionally, this second layer 350may be extruded as a second continuous path. In this illustratedexample, the second path of the second filament (optionally as acontinuous path) forms the following portions of second layer 350: (a) asecond lateral rear heel portion 352 (e.g., extending along and/oradjacent a lateral side 352 s of the ankle/foot opening 364 of thesecond layer 350); (b) a second lateral midfoot portion 354 (e.g.,extending along and/or adjacent a lateral side 354 s of an instepopening 362 (or an inner edge) of the second layer 350); (c) a secondforefoot portion 356 (e.g., which bridges from a lateral side to amedial side of the second layer 350, forward of the midfoot portions);(d) a second medial midfoot portion 358 (e.g., extending along and/oradjacent a medial side 358 s of the instep opening 362 (or an inneredge) of the second layer 350); and (e) a second medial rear heelportion 360 (e.g., extending along and/or adjacent a medial side 360 sof the ankle/foot opening 364 of the second layer 350). The verticaldashed lines shown in FIG. 3B generally define and break the secondlayer 350 into three portions: (a) a posterior third (containing thelateral rear heel portion 352 and the medial rear heel portion 360), (b)a central third (containing the lateral midfoot portion 354 and themedial midfoot portion 358), and (c) an anterior third (containing theforefoot portion 356). In at least some examples of this invention, thesecond layer 350 will consist essentially of, or even consist of, thisfilament structure (optionally formed as a continuous path and/or a onepiece construction). The white space visible in FIG. 3B for this examplesecond layer 350 constitutes open space between filament path segments(e.g., where one can see completely through the second layer 350).

While the path segments of the second layer 350 can be extruded in anydesired order without departing from this invention, in some examples ofthis invention, the outer perimeter (e.g., 350P) may be extruded first,and then the remainder of the layer 350 can be extruded, e.g., in a“raster” like fashion, to fill in the area within the perimeter 350P. Inthis illustrated example, the extruded overall path of the second layer350 lays down the second filament over much of the overall surface areaof the second layer 350 as second plural, non-intersecting, spaced apartpath segments that extend in a substantially medio-lateral direction ofthe second layer 350 (e.g., to help provide the “lock down” or otherfeatures describe above for layer 300). Along the lateral rear heel area352 and the medial rear heel area 360, the second filament path segmentsextend generally from the ankle opening 352 s/360 s to a bottomperimeter portion 352 t/360 t of the second layer 350 (e.g., where thesecond layer 350 will meet a sole structure in a final article offootwear structure), where adjacent path segments of layer 350 extendsubstantially in parallel. Similarly, along the lateral midfoot area 354and the medial midfoot area 358, the second filament path segmentsextend generally from the instep opening 362's inner edges 354 s/358 sto a bottom perimeter portion 354 t/358 t (outer edges) of the secondlayer 350 (e.g., where the second layer 350 will meet a sole structurein a final article of footwear structure), where adjacent path segmentsof layer 350 extend substantially in parallel. At the forefoot region356, the second filament path segments extend generally from the lateralbottom edge 356 s to the medial bottom edge 356 t of the second layer350 (e.g., where the second layer 350 will meet a sole structure in afinal article of footwear structure), where adjacent path segments oflayer 350 extend substantially in parallel. The path segments in thesevarious regions 352, 354, 356, 358, 360 may have any of the featuresand/or options described above for the path segments shown in FIGS.2A-2F.

In the second layer 350, the path segments in one area need not haveconstant spacing from directly adjacent path segments at other areas ofthe second layer 350. For example, as shown in FIG. 3B, the plural,non-intersecting, spaced apart path segments in the forefoot region 356and/or the midfoot regions 354/358 of the second layer 350 are spacedcloser together than are the plural, non-intersecting, spaced apart pathsegments in the heel region(s) 352/360 of the second layer 350. The pathsegment spacings (e.g., S1 to S4 from FIG. 2E) can be selected toprovide desired characteristics for individual regions of the layer 350,the upper, and/or the upper blank 1000 (e.g., desired stretchability,breathability, etc.).

As evident from a comparison of FIGS. 3A and 3B, the path segments offirst layer 300 and second layer 350 extend over a substantial portionof their overall paths in a generally parallel manner. Thus, the pathsegments of the second layer 350 may be extruded generally in paralleland/or to overlap the path segments of the first layer 300 over much oftheir overall path lengths in a manner as shown in FIGS. 2C and 2E. Ifdesired: (a) at least 25% (and in some examples, at least 40%, at least50%, at least 60%, at least 75%, at least 85%, or even at least 90%) ofthe overall path length of the second layer 350 will overlap with pathsegments of the first layer 300 in the manner shown in FIGS. 2C and 2Eand/or (b) at least 25% (and in some examples, at least 40%, at least50%, at least 60%, at least 75%, at least 85%, or even at least 90%) ofthe overall path length of the first layer 300 will overlap with pathsegments of the second layer 350 in the manner shown in FIGS. 2C and 2E.Thus, filaments of the second layer 350 will directly contact filamentsof the first layer 300 (at overlapping contact area 202) as the secondlayer 350 is being extruded. Heat from the second layer 350 as it isbeing extruded (and/or another heat source) causes the second filamentpath segments to fuse together with the first filament path segments atlocation(s) 202 where they contact one another (e.g., the filamentmaterial of the second layer 350 may polymerize with and seamlessly jointhe filament material of the first layer 300). In this manner, the firstlayer 300 of the upper or upper blank 1000 can be fixedly joined to thesecond layer 350 of the upper or upper blank 1000 in an adhesive freemanner at contact location(s) 202 to form the combined first and secondlayers 380 of FIG. 3C. The upper component or intermediate including thecombined first and second layers 380 constitutes a unitary constructionin which the first layer 300 and the second layer 350 are fixed togetheronly in a non-adhesive fused manner. The upper component or intermediateincluding the combined first and second layers 380 may consistessentially of, or even consist of, the first layer 300 and the secondlayer 350.

After the second layer 350 is extruded (e.g., onto first layer 300and/or substrate 106), a third layer 400 of the overall upper or upperblank 1000 then may be applied to the combined first and second layers380. FIG. 3D shows the individual path segments of this example thirdlayer 400, and FIG. 3E schematically shows the production of the thirdlayer 400 onto the previously prepared combined first and second layers380 to create the combined first through third layers 440 of the upperor upper blank 1000. More specifically, FIG. 3D shows a third layer 400formed of a third filament (e.g., having any of the filament featuresand characteristics described above) and formed by extruding a thirdmaterial into multiple path segments (e.g., having any of the pathand/or path segment features described above), e.g., via a soliddeposition modeling process. Optionally, this third layer 400 may beextruded as a third continuous path. In this illustrated example, thethird path of the third filament (optionally as a continuous path) formsthe following portions of the third layer 400: (a) a third lateral rearheel portion 402 (e.g., extending along and/or adjacent a lateral side402 s of the ankle/foot opening 414 of the third layer 400); (b) a thirdlateral midfoot portion 404 (e.g., extending along and/or adjacent alateral side 404 s (or an inner edge) of an instep opening 412 of thethird layer 400); (c) a third forefoot portion 406 (e.g., which bridgesfrom a lateral side to a medial side of the third layer 400, forward ofthe midfoot portions); (d) a third medial midfoot portion 408 (e.g.,extending along and/or adjacent a medial side 408 s (or an inner edge)of the instep opening 412 of the third layer 400); and (e) a thirdmedial rear heel portion 410 (e.g., extending along and/or adjacent amedial side 410 s of the ankle/foot opening 414 of the third layer 400).The vertical dashed lines shown in FIG. 3D generally define and breakthe third layer 400 into three portions: (a) a posterior third(containing the lateral rear heel portion 402 and the medial rear heelportion 410), (b) a central third (containing the lateral midfootportion 404 and the medial midfoot portion 408), and (c) an anteriorthird (containing the forefoot portion 406). In at least some examplesof this invention, the third layer 400 will consist essentially of, oreven consist of, this filament structure (optionally formed as acontinuous path and/or one piece construction). The white space visiblein FIG. 3D for this example third layer 400 constitutes open spacebetween filament path segments (e.g., where one can see completelythrough the third layer 400).

While the path segments of the third layer 400 can be extruded in anydesired order without departing from this invention, in some examples ofthis invention, the outer perimeter (e.g., 400P) may be extruded first,and then the remainder of the third layer 400 can be extruded, e.g., ina “raster” like fashion, to fill in the area within the perimeter 400P.In this illustrated example, the extruded overall path of the thirdlayer 400 lays down the third filament over much of the overall surfacearea of the third layer 400 as third plural, non-intersecting, spacedapart path segments that extend in a substantially anterior-posteriordirection of the third layer 400. As shown in FIG. 3D, in the lateralrear heel portion 402, the lateral midfoot portion 404, the forefootportion 406, and the medial rear heel portion 410, the third plural,non-intersecting path segments of the third layer 400 extend in a gentlycurved manner in a direction from the rear heel portion 402/410 forward.In the medial midfoot portion 408, however, at least some of the thirdplural, non-intersecting, spaced apart path segments extend in aserpentine configuration including at least two peaks (408P) and atleast two valleys (408V). The path segments in these various regions402, 404, 406, 408, 410 may have any of the features and/or optionsdescribed above for the path segments shown in FIGS. 2A-2F.

As further shown in FIG. 3D, the third path of filament defines a firstinner edge at lateral instep opening edge 404 s, a first outer edge 404t at lateral midfoot region 404, a second inner edge at medial instepopening edge 408 s, and a second outer edge 408 t at medial midfootregion 408. An instep opening 412 for the third layer 400 is definedbetween the first inner edge at 404 s and the second inner edge at 408s. The third path of the filament in this example layer 400 includes:(a) first plural, non-intersecting, spaced apart path segments locatedbetween the first inner edge at 404 s and the first outer edge 404 t,wherein the first plural, non-intersecting, spaced apart path segmentsof the third path are linear and/or curved without defining plural peaksand valleys and/or (b) second plural, non-intersecting, spaced apartpath segments located between the second inner edge at 408 s and thesecond outer edge 408 t, wherein a plurality of the second plural,non-intersecting, spaced apart path segments of the third continuouspath located between the second inner edge at 408 s and the second outeredge 408 t extend in a serpentine configuration and have at least twopeaks 408P and at least two valleys 408V. The third layer 400 of FIG. 3Dmay include at least 4 path segments, at least 6 path segments, at least8 path segments, at least 10 path segments, or even at least 12 pathsegments that extend substantially in parallel and/or have the notedserpentine configuration.

In the third layer 400, the path segments in one area need not haveconstant spacing from directly adjacent path segments at other areas ofthe third layer 400. For example, as shown in FIG. 3D, the plural,non-intersecting, spaced apart path segments in the forefoot region 406of the third layer 400 are spaced closer together than are the plural,non-intersecting, spaced apart path segments in the midfoot region(s)404/408 and/or the plural, non-intersecting, spaced apart path segmentsin the forefoot region 406 and/or the midfoot region(s) 404/408 arespaced closer together than are the plural, non-intersecting, spacedapart path segments in the heel region(s) 402/410 of the third layer400.

As evident from a comparison of FIG. 3D with FIGS. 3A and 3B, the pathsegments of third layer 400 will substantially intersect the pathsegments of the first layer 300 and the second layer 350 over asubstantial portion of their overall paths. The intersecting pathsegments form a grid or generally matrix pattern, which can be seen inthe combined first through third layers 440 shown in FIG. 3E. The pathsegments of the third layer 400 may intersect the path segments of thefirst layer 300 and/or the second layer 350 at any desired angles, e.g.,from 5° to 175°, and in some examples, from 15° to 165°, from 25° to155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60 ° to120 °, from 65° to 90°, etc. In at least some examples of thisinvention: (a) the third path of the third layer 400 will overlap thefirst path of the first layer 300 over less than 50% (and in someexamples less than 40%, less than 30%, less than 20%, or even less than10%) of an overall length of the third path, (b) the third path of thethird layer 400 will overlap the second path of the second layer 350over less than 50% (and in some examples less than 40%, less than 30%,less than 20%, or even less than 10%) of an overall length of the thirdpath, (c) the third path of the third layer 400 will overlap the firstpath of the first layer 300 over less than 50% (and in some examplesless than 40%, less than 30%, less than 20%, or even less than 10%) ofan overall length of the first path, and/or (d) the third path of thethird layer will overlap the second path of the second layer 350 overless than 50% (and in some examples less than 40%, less than 30%, lessthan 20%, or even less than 10%) of an overall length of the secondpath.

Thus, filaments of the third layer 400 will directly contact filamentsof the first layer 300 and the filaments of the second layer (atintersecting contact area 202) as the third layer 400 is being extruded.Heat from the third layer 400 as it is being extruded (and/or anotherheat source) causes the third filament path segments to fuse togetherwith either or both of the first filament path segments and/or thesecond filament path segments at location(s) 202 where the thirdfilament path segments contact either or both of the first filament pathsegments and/or the second filament path segments (e.g., the filamentmaterial of the third layer 400 may polymerize with and seamlessly jointhe filament materials of the first layer 300 and/or the second layer350). In this manner, the third layer 400 of the upper or upper blank1000 can be fixedly joined to the first layer 300 and the second layer350 of the upper or upper blank 1000 in an adhesive free manner atcontact location(s) 202 to form the combined first through third layers440. The upper component or intermediate including the combined firstthrough third layers 440 constitutes a unitary construction in which thefirst layer 300, the second layer 350, and the third layer 400 are fixedtogether only in a non-adhesive fused manner. The upper component orintermediate including the combined first and third layers 440 mayconsist essentially of, or even consist of, the first layer 300, thesecond layer 350, and the third layer 400.

After the third layer 400 is extruded (e.g., onto first layer 300,second layer 350, and/or substrate 106), a fourth layer 500 of theoverall upper or upper blank 1000 then may be applied to the combinedfirst through third layers 440. FIG. 3F shows the individual pathsegments of this example fourth layer 500, and FIG. 3G schematicallyshows the production of the fourth layer 500 onto the previouslyprepared combined first through third layers 440 to create the combinedfirst through fourth layers 540 of the upper or upper blank 1000. Morespecifically, FIG. 3F shows a fourth layer 500 formed of a fourthfilament (e.g., having any of the filament features and characteristicsdescribed above) and formed by extruding a fourth material into multiplepath segments (e.g., having any of the path and/or path segment featuresdescribed above), e.g., via a solid deposition modeling process.Optionally, this fourth layer 500 may be extruded as a fourth continuouspath. In this illustrated example, the fourth path of the fourthfilament (optionally as a continuous path) forms the following portionsof the fourth layer 500: (a) a fourth lateral rear heel portion 502(e.g., extending along and/or adjacent a lateral side 502 s of theankle/foot opening 514 of the fourth layer 500); (b) a fourth lateralmidfoot portion 504 (e.g., extending along and/or adjacent a lateralside 504 s (or an inner edge) of an instep opening 512 of the fourthlayer 500); (c) a fourth forefoot portion 506 (e.g., which bridges froma lateral side to a medial side of the fourth layer 500, forward of themidfoot portions); (d) a fourth medial midfoot portion 508 (e.g.,extending along and/or adjacent a medial side 508 s (or an inner edge)of the instep opening 512 of the fourth layer 500); and (e) a fourthmedial rear heel portion 510 (e.g., extending along and/or adjacent amedial side 510 s of the ankle/foot opening 514 of the fourth layer500). The vertical dashed lines shown in FIG. 3F generally define andbreak the fourth layer 500 into three portions: (a) a posterior third(containing the lateral rear heel portion 502 and the medial rear heelportion 510), (b) a central third (containing the lateral midfootportion 504 and the medial midfoot portion 508), and (c) an anteriorthird (containing the forefoot portion 506). In at least some examplesof this invention, the fourth layer 500 will consist essentially of, oreven consist of, this filament structure (optionally formed as acontinuous path and/or a one piece construction). The white spacevisible in FIG. 3F for this example fourth layer 500 constitutes openspace between filament path segments (e.g., where one can see completelythrough the fourth layer 500).

While the path segments of the fourth layer 500 can be extruded in anydesired order without departing from this invention, in some examples ofthis invention, the outer perimeter (e.g., 500P) may be extruded first,and then the remainder of the fourth layer 500 can be extruded, e.g., ina “raster” like fashion, to fill in the area within the perimeter 500P.In this illustrated example, the extruded overall path of the fourthlayer 500 lays down the fourth filament over much of the overall surfacearea of the fourth layer 500 as fourth plural, non-intersecting, spacedapart path segments that extend in a substantially anterior-posteriordirection of the fourth layer 500. As shown in FIG. 3F, in the lateralrear heel portion 502, the lateral midfoot portion 504, the forefootportion 506, and the medial rear heel portion 510, the fourth plural,non-intersecting path segments extend in a gently curved manner in adirection from the rear heel portion 502/510 forward. In the medialmidfoot portion 508, however, at least some of the fourth plural,non-intersecting, spaced apart path segments of the fourth layer 500extend in a serpentine configuration including at least two peaks (508P)and at least two valleys (508V). The path segments in these variousregions 502, 504, 506, 508, 510 may have any of the features and/oroptions described above for the path segments shown in FIGS. 2A-2F.

As further shown in FIG. 3F, the fourth path of filament defines a firstinner edge at lateral instep opening edge 504 s, a first outer edge 504t at lateral midfoot region 504, a second inner edge at medial instepopening edge 508 s, and a second outer edge 508 t at medial midfootregion 508. An instep opening 512 for the fourth layer 500 is definedbetween the first inner edge at 504 s and the second inner edge at 508s. The fourth path of the filament in this example layer 500 includes:(a) first plural, non-intersecting, spaced apart path segments locatedbetween the first inner edge at 504 s and the first outer edge 504 t,wherein the first plural, non-intersecting, spaced apart path segmentsof the fourth path are linear and/or curved without defining pluralpeaks and valleys and/or (b) second plural, non-intersecting, spacedapart path segments located between the second inner edge at 508 s andthe second outer edge 508 t, wherein a plurality of the second plural,non-intersecting, spaced apart path segments of the fourth path locatedbetween the second inner edge at 508 s and the second outer edge 508 textend in a serpentine configuration and have at least two peaks 508Pand at least two valleys 508V. The fourth layer 500 of FIG. 3F mayinclude at least 4 path segments, at least 6 path segments, at least 8path segments, at least 10 path segments, or even at least 12 pathsegments that extend substantially in parallel and/or have the notedserpentine configuration.

As evident from a comparison of FIGS. 3D and 3F, the path segments ofthird layer 400 and fourth layer 500 extend over a substantial portionof their overall paths in a generally parallel manner. Thus, the pathsegments of the fourth layer 500 may be extruded generally in paralleland/or to overlap the path segments of the third layer 400 over much oftheir overall path lengths in a manner as shown in FIGS. 2C and 2E. Ifdesired: (a) at least 25% (and in some examples, at least 40%, at least50%, at least 60%, at least 75%, at least 85%, or even at least 90%) ofthe overall path length of the fourth layer 500 will overlap with pathsegments of the third layer 400 in the manner shown in FIGS. 2C and 2Eand/or (b) at least 25% (and in some examples, at least 40%, at least50%, at least 60%, at least 75%, at least 85%, or even at least 90%) ofthe overall path length of the third layer 400 will overlap with pathsegments of the fourth layer 500 in the manner shown in FIGS. 2C and 2E.In at least some examples of this invention: (a) the fourth path of thefourth layer 500 will overlap the first path of the first layer 300 overless than 50% (and in some examples less than 40%, less than 30%, lessthan 20%, or even less than 10%) of an overall length of the fourthpath, (b) the fourth path of the fourth layer 500 will overlap thesecond path of the second layer 350 over less than 50% (and in someexamples less than 40%, less than 30%, less than 20%, or even less than10%) of an overall length of the fourth path, (c) the fourth path of thefourth layer 500 will overlap the first path of the first layer 300 overless than 50% (and in some examples less than 40%, less than 30%, lessthan 20%, or even less than 10%) of an overall length of the first path,and/or (d) the fourth path of the fourth layer 500 will overlap thesecond path of the second layer 350 over less than 50% (and in someexamples less than 40%, less than 30%, less than 20%, or even less than10%) of an overall length of the second path.

Thus, filaments of the fourth layer 500 will directly contact filamentsof the third layer 400 (at overlapping contact area 202) as the fourthlayer 500 is being extruded. Heat from the fourth layer 500 as it isbeing extruded (and/or another heat source) causes the fourth filamentpath segments to fuse together with the third filament path segments atlocation(s) 202 where they contact one another (e.g., the filamentmaterial of the fourth layer 500 may polymerize with and seamlessly jointhe filament material of the third layer 400). In this manner, the thirdlayer 400 of the upper or upper blank 1000 can be fixedly joined to thefourth layer 500 of the upper or upper blank 1000 in an adhesive freemanner at contact location(s) 202.

As also evident from a comparison of FIG. 3F with FIGS. 3A and 3B, thepath segments of fourth layer 500 will substantially intersect the pathsegments of the first layer 300 and the second layer 350 over asubstantial portion of their overall paths. The intersecting pathsegments form a grid or generally matrix pattern, which can be seen inthe combined first through fourth layers 540 shown in FIG. 3G. The pathsegments of the fourth layer 500 may intersect the path segments of thefirst layer 300 and/or the second layer 350 at any desired angles, e.g.,from 5° to 175°, and in some examples, from 15° to 165°, from 25° to155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to120°, from 65° to 90°, etc. Thus, filaments of the fourth layer 500 willdirectly contact filaments of the first layer 300 and filaments of thesecond layer 350 (at intersecting contact area 202) as the fourth layer500 is being extruded. Heat from the fourth layer 500 as it is beingextruded (and/or another heat source) causes the fourth filament pathsegments to fuse together with either or both of the first filament pathsegments and/or the second filament path segments at location(s) 202where the fourth filament path segments contact either or both of thefirst filament path segments and/or the second filament path segments(e.g., the filament material of the fourth layer 500 may polymerize withand seamlessly join the filament materials of the first layer 300 and/orthe second layer 350).

In these manners, the fourth layer 500 of the upper or upper blank 1000can be fixedly joined to the first layer 300, the second layer 350, andthe third layer 400 of the upper or upper blank 1000 in an adhesive freemanner at contact location(s) 202 to form the combined first throughfourth layers 540. The upper component or intermediate including thecombined first through fourth layers 540 constitutes a unitaryconstruction in which the first layer 300, the second layer 350, thethird layer 400, and the fourth layer 500 are fixed together only in anon-adhesive fused manner. The upper component or intermediate includingthe combined first through fourth layers 540 may consist essentially of,or even consist of, the first layer 300, the second layer 350, the thirdlayer 400, and the fourth layer 500.

In the fourth layer 500, the path segments in one area need not haveconstant spacing from directly adjacent path segments at other areas ofthe fourth layer 500. For example, as shown in FIG. 3F, the plural,non-intersecting, spaced apart path segments in the forefoot region 506of the fourth layer 500 are spaced closer together than are the plural,non-intersecting, spaced apart path segments in the midfoot region(s)504/508 and/or the plural, non-intersecting, spaced apart path segmentsin the forefoot region 506 and/or the midfoot region(s) 504/508 arespaced closer together than are the plural, non-intersecting, spacedapart path segments in the heel region(s) 502/510 of the fourth layer500.

After the fourth layer 500 is extruded (e.g., onto first layer 300,second layer 350, third layer 400, and/or substrate 106), a fifth layer600 of the overall upper or upper blank 1000 then may be applied to thecombined first through fourth layers 540. FIG. 3H shows the individualpath segments of this example fifth layer 600, and FIG. 3I schematicallyshows the production of the fifth layer 600 onto the previously preparedcombined first through fourth layers 540 to create the combined firstthrough fifth layers 640 of the upper or upper blank 1000. Morespecifically, FIG. 3H shows a fifth layer 600 formed of a fifth filament(e.g., having any of the filament features and characteristics describedabove) and formed by extruding a fifth material into multiple pathsegments (e.g., having any of the path and/or path segment featuresdescribed above), e.g., via a solid deposition modeling process.Optionally, this fifth layer 600 may be extruded as a fifth continuouspath. In this illustrated example, the fifth path of the fifth filament(optionally as a continuous path) forms the following portions of thefifth layer 600: (a) a fifth lateral rear heel portion 602 (e.g.,extending along and/or adjacent a lateral side 602 s of the ankle/footopening 614 of the fifth layer 600); (b) a fifth lateral midfoot portion604 (e.g., extending along and/or adjacent a lateral side 604 s (or aninner edge) of an instep opening 612 of the fifth layer 600); (c) afifth forefoot portion 606 (e.g., which bridges from a lateral side to amedial side of the fifth layer 600, forward of the midfoot portions);(d) a fifth medial midfoot portion 608 (e.g., extending along and/oradjacent a medial side 608 s of the instep opening 612 of the fifthlayer 600); and (e) a fifth medial rear heel portion 610 (e.g.,extending along and/or adjacent a medial side 610 s (or an inner edge)of the ankle/foot opening 614 of the fifth layer 600). The verticaldashed lines shown in FIG. 3H generally define and break the fifth layer600 into three portions: (a) a posterior third (containing the lateralrear heel portion 602 and the medial rear heel portion 610), (b) acentral third (containing the lateral midfoot portion 604 and the medialmidfoot portion 608), and (c) an anterior third (containing the forefootportion 606). In at least some examples of this invention, the fifthlayer 600 will consist essentially of, or even consist of, this filamentstructure (optionally formed as a continuous path and/or one piececonstruction). The white space visible in FIG. 3H for this example fifthlayer 600 constitutes open space between filament path segments (e.g.,where one can see completely through the fifth layer 600).

While the path segments of the fifth layer 600 can be extruded in anydesired order without departing from this invention, in some examples ofthis invention, the outer perimeter (e.g., 600P) may be extruded first,and then the remainder of the fifth layer 600 can be extruded, e.g., ina “raster” like fashion, to fill in the area within the perimeter 600P.In this illustrated example, the extruded overall path of the fifthlayer 600 lays down the fifth filament over much of the overall surfacearea of the fifth layer 600 as fifth plural, non-intersecting, spacedapart path segments that extend in a substantially anterior-posteriordirection of the fifth layer 600. As shown in FIG. 3H, in the lateralrear heel portion 602, the lateral midfoot portion 604, the forefootportion 606, and the medial rear heel portion 610, the fifth plural,non-intersecting path segments of the fifth layer 600 extend in a gentlycurved manner in a direction from the rear heel portion 602/610 forward.In the medial midfoot portion 608, however, at least some of the fifthplural, non-intersecting, spaced apart path segments extend in aserpentine configuration including at least two peaks (608P) and atleast two valleys (608V). The path segments in these various regions602, 604, 606, 608, 610 may have any of the features and/or optionsdescribed above for the path segments shown in FIGS. 2A-2F.

As further shown in FIG. 3H, the fifth path of filament defines a firstinner edge at lateral instep opening edge 604 s, a first outer edge 604t at lateral midfoot region 604, a second inner edge at medial instepopening edge 608 s, and a second outer edge 608 t at medial midfootregion 608. An instep opening 612 for the fifth layer 600 is definedbetween the first inner edge at 604 s and the second inner edge at 608s. The fifth path of the filament in this example layer 600 includes:(a) first plural, non-intersecting, spaced apart path segments locatedbetween the first inner edge at 604 s and the first outer edge 604 t,wherein the first plural, non-intersecting, spaced apart path segmentsof the fifth path are linear and/or curved without defining plural peaksand valleys and/or (b) second plural, non-intersecting, spaced apartpath segments located between the second inner edge at 608 s and thesecond outer edge 608 t, wherein a plurality of the second plural,non-intersecting, spaced apart path segments of the fifth path locatedbetween the second inner edge at 608 s and the second outer edge 608 textend in a serpentine configuration and have at least two peaks 608Pand at least two valleys 608V. The fifth layer 600 of FIG. 3H mayinclude at least 4 path segments, at least 6 path segments, at least 8path segments, at least 10 path segments, or even at least 12 pathsegments that extend substantially in parallel and/or have the notedserpentine configuration.

As evident from a comparison of FIGS. 3D, 3F, and 3H, the path segmentsof third layer 400, fourth layer 500, and fifth layer 600 extend over asubstantial portion of their overall paths in a generally parallelmanner. Thus, the path segments of the fifth layer 600 may be extrudedgenerally in parallel and/or to overlap the path segments of the thirdlayer 400 and/or the fourth layer 500 over much of their overall pathlengths in a manner as shown in FIGS. 2C and 2E. If desired: (a) atleast 25% (and in some examples, at least 40%, at least 50%, at least60%, at least 75%, at least 85%, or even at least 90%) of the overallpath length of the fifth layer 600 will overlap with path segments of atleast one of the third layer 400 and/or the fourth layer 500 in themanner shown in FIGS. 2C and 2E and/or (b) at least 25% (and in someexamples, at least 40%, at least 50%, at least 60%, at least 75%, atleast 85%, or even at least 90%) of the overall path length of the thirdlayer 400 and/or the fourth layer 500 will overlap with path segments ofthe fifth layer 600 in the manner shown in FIGS. 2C and 2E. In at leastsome examples of this invention: (a) the fifth path of the fifth layer600 will overlap the first path of the first layer 300 over less than50% (and in some examples less than 40%, less than 30%, less than 20%,or even less than 10%) of an overall length of the fifth path, (b) thefifth path of the fifth layer 600 will overlap the second path of thesecond layer 350 over less than 50% (and in some examples less than 40%,less than 30%, less than 20%, or even less than 10%) of an overalllength of the fifth path, (c) the fifth path of the fifth layer 600 willoverlap the first path of the first layer 300 over less than 50% (and insome examples less than 40%, less than 30%, less than 20%, or even lessthan 10%) of an overall length of the first path, and/or (d) the fifthpath of the fifth layer 600 will overlap the second path of the secondlayer 350 over less than 50% (and in some examples less than 40%, lessthan 30%, less than 20%, or even less than 10%) of an overall length ofthe second path.

Thus, filaments of the fifth layer 600 will directly contact filamentsof the third layer 400 and/or the fourth layer 500 (at overlappingcontact area 202) as the fifth layer 600 is being extruded. Heat fromthe fifth layer 600 as it is being extruded (and/or another heat source)causes the fifth filament path segments to fuse together with either orboth of the third filament path segments and/or the fourth filament pathsegments at location(s) 202 where the fifth filament path segmentscontact either or both of the third filament path segments and/or thefourth filament path segments (e.g., the filament material of the fifthlayer 600 may polymerize with and seamlessly join the filament materialof the third layer 400 and/or the fourth layer 500). In this manner, thethird layer 400 and/or fourth layer 500 of the upper or upper blank 1000can be fixedly joined to the fifth layer 500 of the upper or upper blank1000 in an adhesive free manner at contact location(s) 202.

As also evident from a comparison of FIG. 3H with FIGS. 3A and 3B, thepath segments of fifth layer 600 will substantially intersect the pathsegments of the first layer 300 and the second layer 350 over asubstantial portion of their overall paths. The intersecting pathsegments form a grid or generally matrix pattern, which can be seen inthe combined first through fifth layers 640 shown in FIG. 3I. The pathsegments of the fifth layer 600 may intersect the path segments of thefirst layer 300 and/or the second layer 350 at any desired angles, e.g.,from 5° to 175°, and in some examples, from 15° to 165°, from 25° to155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to120°, from 65° to 90°, etc. Thus, filaments of the fifth layer 600 willdirectly contact filaments of the first layer 300 and filaments of thesecond layer 350 (at intersecting contact area 202) as the fifth layer600 is being extruded. Heat from the fifth layer 600 as it is beingextruded (and/or another heat source) causes the fifth filament pathsegments to fuse together with either or both of the first filament pathsegments and/or the second filament path segments at location(s) 202where the fifth filament path segments contact either or both of thefirst filament path segments and/or the second filament path segments(e.g., the filament material of the fifth layer 600 may polymerize withand seamlessly join the filament materials of the first layer 300 and/orthe second layer 350).

In these manners, the fifth layer 600 of the upper or upper blank 1000can be fixedly joined to the first layer 300, the second layer 350, thethird layer 400, and the fourth layer 500 of the upper or upper blank1000 in an adhesive free manner at contact location(s) 202 to form thecombined first through fifth layers 640. The upper component orintermediate including the combined first through fifth layers 640constitutes a unitary construction in which the first layer 300, thesecond layer 350, the third layer 400, the fourth layer 500, and thefifth layer 600 are fixed together only in a non-adhesive fused manner.The upper component or intermediate including the combined first throughfifth layers 640 may consist essentially of, or even consist of, thefirst layer 300, the second layer 350, the third layer 400, the fourthlayer 500, and the fifth layer 600.

In the fifth layer 600, the path segments in one area need not haveconstant spacing from directly adjacent path segments at other areas ofthe fifth layer 600. For example, as shown in FIG. 3H, the plural,non-intersecting, spaced apart path segments in the forefoot region 606of the fifth layer 600 are spaced closer together than are the plural,non-intersecting, spaced apart path segments in the midfoot region(s)604/608 and/or the plural, non-intersecting, spaced apart path segmentsin the forefoot region 606 and/or the midfoot region(s) 604/608 arespaced closer together than are the plural, non-intersecting, spacedapart path segments in the heel region(s) 602/610 of the fifth layer600.

After the fifth layer 600 is extruded (e.g., onto first layer 300,second layer 350, third layer 400, fourth layer 500, and/or substrate106), a sixth layer 700 of the overall upper or upper blank 1000 thenmay be applied to the combined first through fifth layers 640. FIG. 3Jshows the individual path segments of this example sixth layer 700, andFIG. 3K schematically shows the production of the sixth layer 700 ontothe previously prepared combined first through fifth layers 640 tocreate the combined first through sixth layers 740 of the upper or upperblank 1000. More specifically, FIG. 3J shows a sixth layer 700 formed ofa sixth filament (e.g., having any of the filament features andcharacteristics described above) and formed by extruding a sixthmaterial into multiple path segments (e.g., having any of the pathand/or path segment features described above), e.g., via a soliddeposition modeling process. Optionally, this sixth layer 700 may beextruded as a sixth continuous path. In this illustrated example, thesixth path of the sixth filament (optionally as a continuous path) formsthe following portions of the sixth layer 700: (a) a sixth lateral rearheel portion 702 (e.g., extending along and/or adjacent a lateral side702 s of the ankle/foot opening 714 of the sixth layer 700); (b) a sixthlateral midfoot portion 704 (e.g., extending along and/or adjacent alateral side 704 s (or an inner edge) of an instep opening 712 of thesixth layer 700); (c) a sixth forefoot portion 706 (e.g., which bridgesfrom a lateral side to a medial side of the sixth layer 700, forward ofthe midfoot portions); (d) a sixth medial midfoot portion 708 (e.g.,extending along and/or adjacent a medial side 708 s (or an inner edge)of the instep opening 712 of the sixth layer 700); and (e) a sixthmedial rear heel portion 710 (e.g., extending along and/or adjacent amedial side 710 s of the ankle/foot opening 714 of the sixth layer 700).The vertical dashed lines shown in FIG. 3J generally define and breakthe sixth layer 700 into three portions: (a) a posterior third(containing the lateral rear heel portion 702 and the medial rear heelportion 710), (b) a central third (containing the lateral midfootportion 704 and the medial midfoot portion 708), and (c) an anteriorthird (containing the forefoot portion 706). In at least some examplesof this invention, the sixth layer 700 will consist essentially of, oreven consist of, this filament structure (optionally formed as acontinuous path and/or a one piece construction). The white spacevisible in FIG. 3J for this example sixth layer 700 constitutes openspace between filament path segments (e.g., where one can see completelythrough the sixth layer 700).

While the path segments of the sixth layer 700 can be extruded in anydesired order without departing from this invention, in some examples ofthis invention, the outer perimeter (e.g., 700P) may be extruded first,and then the remainder of the sixth layer 700 can be extruded, e.g., ina “raster” like fashion, to fill in the area within the perimeter 700P.In this illustrated example, the extruded overall path of the sixthlayer 700 lays down the sixth filament over much of the overall surfacearea of the sixth layer 700 as sixth plural, non-intersecting, spacedapart path segments that extend in a substantially anterior-posteriordirection of the sixth layer 700. As shown in FIG. 3J, in the lateralrear heel portion 702, the forefoot portion 706, the medial midfootportion 708, and the medial rear heel portion 710, the sixth plural,non-intersecting path segments of the sixth layer 700 extend in a gentlycurved manner in a direction from the rear heel portion 702/710 forward.In the lateral midfoot portion 704, however, at least some of the sixthplural, non-intersecting, spaced apart path segments extend in aserpentine configuration including at least two peaks (708P) and atleast two valleys (708V). The path segments in these various regions702, 704, 706, 708, 710 may have any of the features and/or optionsdescribed above for the path segments shown in FIGS. 2A-2F.

As further shown in FIG. 3J, the sixth path of filament defines a firstinner edge at lateral instep opening edge 704 s, a first outer edge 704t at lateral midfoot region 704, a second inner edge at medial instepopening edge 708 s, and a second outer edge 708 t at medial midfootregion 708. An instep opening 712 for the sixth layer 700 is definedbetween the first inner edge at 704 s and the second inner edge at 708s. The sixth path of the filament in this example layer 700 includes:(a) first plural, non-intersecting, spaced apart path segments locatedbetween the first inner edge at 704 s and the first outer edge 704 t,wherein a plurality of the first plural, non-intersecting, spaced apartpath segments of the sixth path located between the first inner edge at704 s and the first outer edge 704 t extend in a serpentineconfiguration and have at least two peaks 708P and at least two valleys708V and (b) second plural, non-intersecting, spaced apart path segmentslocated between the second inner edge at 708 s and the second outer edge708 t, wherein the second, plural, non-intersecting, spaced apart pathsegments of the sixth path are linear and/or curved without definingplural peaks and valleys. The sixth layer 700 of FIG. 3J may include atleast 4 path segments, at least 6 path segments, at least 8 pathsegments, at least 10 path segments, or even at least 12 path segmentsthat extend substantially in parallel and/or have the noted serpentineconfiguration.

In the sixth layer 700, the path segments in one area need not haveconstant spacing from directly adjacent path segments at other areas ofthe sixth layer 700. For example, as shown in FIG. 3J, the plural,non-intersecting, spaced apart path segments in the forefoot region 706of the sixth layer 700 are spaced closer together than are the plural,non-intersecting, spaced apart path segments in the midfoot region(s)704/708 and/or the plural, non-intersecting, spaced apart path segmentsin the forefoot region 706 and/or the midfoot region(s) 704/708 arespaced closer together than are the plural, non-intersecting, spacedapart path segments in the heel region(s) 702/710 of the sixth layer700.

As evident from a comparison of FIG. 3J with FIGS. 3A, 3B, 3D, 3F, and3H, the path segments of sixth layer 700 will substantially intersectthe path segments of the first layer 300, the second layer 350, thethird layer 400, the fourth layer 500, and the fifth layer 600 over asubstantial portion of their overall paths. The intersecting pathsegments form generally diamond shapes, which can be seen in thecombined first through sixth layers 740 shown in FIG. 3K. The pathsegments of the sixth layer 700 may intersect the path segments of thefirst layer 300, the second layer 350, the third layer 400, the fourthlayer 500, and/or the fifth layer 600 at any desired angles, e.g., from5° to 175°, and in some examples, from 15° to 165°, from 25° to 155°,from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to 120°,from 65° to 90°, etc. In at least some examples of this invention: (a)the sixth path of the sixth layer 700 will overlap with one or more ofthe first path of the first layer 300, the second path of the secondlayer 350, the third path of the third layer 400, the fourth path of thefourth layer 500, and/or the fifth path of the fifth layer 600 over lessthan 50% (and in some examples less than 40%, less than 30%, less than20%, or even less than 10%) of an overall length of the sixth path,and/or (b) the sixth path of the sixth layer 700 will overlap one ormore of the first path of the first layer 300, the second path of thesecond layer 350, the third path of the third layer 400, the fourth pathof the fourth layer 500, and/or the fifth path of the fifth layer 600over less than 50% (and in some examples less than 40%, less than 30%,less than 20%, or even less than 10%) of an overall length of therespective first path, second path, third path, fourth path, and/orfifth path.

Thus, filaments of the sixth layer 700 will directly contact filamentsof the first layer 300, filaments of the second layer 350, filaments ofthe third layer 400, filaments of the fourth layer 500, and/or filamentsof the fifth layer 600 (at intersecting contact area 202) as the sixthlayer 700 is being extruded. Heat from the sixth layer 700 as it isbeing extruded (and/or another heat source) causes the sixth filamentpath segments to fuse together with any one of or any combination of thefirst filament path segments, the second filament path segments, thethird filament path segments, the fourth filament path segments, and/orthe fifth filament path segments at location(s) 202 where the sixthfilament path segments contact any one of or any combination of thefirst filament path segments, the second filament path segments, thethird filament path segments, the fourth filament path segments, and/orthe fifth filament path segments (e.g., the filament material of thesixth layer 700 may polymerize with and seamlessly join the filamentmaterials of the first layer 300, the second layer 350, the third layer400, the fourth layer 500, and/or the fifth layer 600). In this manner,the sixth layer 700 of the upper or upper blank 1000 can be fixedlyjoined to the first layer 300, the second layer 350, the third layer400, the fourth layer 500, and/or the fifth layer 600 of the upper orupper blank 1000 in an adhesive free manner at contact location(s) 202to form the combined first through sixth layers 740. The upper componentor intermediate including the combined first through sixth layers 740constitutes a unitary construction in which the first layer 300, thesecond layer 350, the third layer 400, the fourth layer 500, the fifthlayer 600, and the sixth layer 700 are fixed together only in anon-adhesive fused manner. The upper component or intermediate includingthe combined first through sixth layers 740 may consist essentially of,or even consist of, the first layer 300, the second layer 350, the thirdlayer 400, the fourth layer 500, the fifth layer 600, and the sixthlayer 700.

After the sixth layer 700 is extruded (e.g., onto first layer 300,second layer 350, third layer 400, fourth layer 500, fifth layer 600,and/or substrate 106), a seventh layer 800 of the overall upper or upperblank 1000 then may be applied to the combined first through sixthlayers 740. FIG. 3L shows the individual path segments of this exampleseventh layer 800, and FIG. 3M schematically shows the production of theseventh layer 800 onto the previously prepared combined first throughsixth layers 740 to create the combined first through seventh layers 840of the upper or upper blank 1000. More specifically, FIG. 3L shows aseventh layer 800 formed of a seventh filament (e.g., having any of thefilament features and characteristics described above) and formed byextruding a seventh material into multiple path segments (e.g., havingany of the path and/or path segment features described above), e.g., bya solid deposition modeling process. Optionally, this seventh layer 800may be extruded as a seventh continuous path. In this illustratedexample, the seventh path of the seventh filament (optionally as acontinuous path) forms the following portions of the seventh layer 800:(a) a seventh lateral rear heel portion 802 (e.g., extending alongand/or adjacent a lateral side 802 s of the ankle/foot opening 814 ofthe seventh layer 800); (b) a seventh lateral midfoot portion 804 (e.g.,extending along and/or adjacent a lateral side 804 s (or an inner edge)of an instep opening 812 of the seventh layer 800); (c) a seventhforefoot portion 806 (e.g., which bridges from a lateral side to amedial side of the seventh layer 800, forward of the midfoot portions);(d) a seventh medial midfoot portion 808 (e.g., extending along and/oradjacent a medial side 808 s (or an inner edge) of the instep opening812 of the seventh layer 800); and (e) a seventh medial rear heelportion 810 (e.g., extending along and/or adjacent a medial side 810 sof the ankle/foot opening 814 of the seventh layer 800). The verticaldashed lines shown in FIG. 3L generally define and break the seventhlayer 800 into three portions: (a) a posterior third (containing thelateral rear heel portion 802 and the medial rear heel portion 810), (b)a central third (containing the lateral midfoot portion 804 and themedial midfoot portion 808), and (c) an anterior third (containing theforefoot portion 806). In at least some examples of this invention, theseventh layer 800 will consist essentially of, or even consist of, thisfilament structure (optionally formed as a continuous path and/or as aone piece construction). The white space visible in FIG. 3L for thisexample seventh layer 800 constitutes open space between filament pathsegments (e.g., where one can see completely through the seventh layer800).

While the path segments of the seventh layer 800 can be extruded in anydesired order without departing from this invention, in some examples ofthis invention, the outer perimeter (e.g., 800P) may be extruded first,and then the remainder of the seventh layer 800 can be extruded, e.g.,in a “raster” like fashion, to fill in the area within the perimeter800P. In this illustrated example, the extruded overall path of theseventh layer 800 lays down the seventh filament over much of theoverall surface area of the seventh layer 800 as seventh plural,non-intersecting, spaced apart path segments that extend in asubstantially anterior-posterior direction of the seventh layer 800. Asshown in FIG. 3L, in the lateral rear heel portion 802, the forefootportion 806, the medial midfoot portion 808, and the medial rear heelportion 810, the seventh plural, non-intersecting path segments extendin a gently curved manner in a direction from the rear heel portion802/810 forward. In the lateral midfoot portion 804, however, at leastsome of the seventh plural, non-intersecting, spaced apart path segmentsextend in a serpentine configuration including at least two peaks (808P)and at least two valleys (808V). The path segments in these variousregions 802, 804, 806, 808, 810 may have any of the features and/oroptions described above for the path segments shown in FIGS. 2A-2F.

As further shown in FIG. 3L, the seventh path of filament defines afirst inner edge at lateral instep opening edge 804 s, a first outeredge 804 t at lateral midfoot region 804, a second inner edge at medialinstep opening edge 808 s, and a second outer edge 808 t at medialmidfoot region 808. An instep opening 812 for the seventh layer 800 isdefined between the first inner edge at 804 s and the second inner edgeat 808 s. The seventh path of the filament in this example layer 800includes: (a) first plural, non-intersecting, spaced apart path segmentslocated between the first inner edge at 804 s and the first outer edge804 t, wherein a plurality of the first plural, non-intersecting, spacedapart path segments of the seventh path located between the first inneredge at 804 s and the first outer edge 804 t extend in a serpentineconfiguration and have at least two peaks 808P and at least two valleys808V and (b) second plural, non-intersecting, spaced apart path segmentslocated between the second inner edge at 808 s and the second outer edge808 t, wherein the second, plural, non-intersecting, spaced apart pathsegments of the seventh path are linear and/or curved without definingplural peaks and valleys. The seventh layer 800 of FIG. 3L may includeat least 4 path segments, at least 6 path segments, at least 8 pathsegments, at least 10 path segments, or even at least 12 path segmentsthat extend substantially in parallel and/or have the noted serpentineconfiguration.

As evident from a comparison of FIGS. 3J and 3L, the path segments ofsixth layer 700 and seventh layer 800 extend over a substantial portionof their overall paths in a generally parallel manner. Thus, the pathsegments of the seventh layer 800 may be extruded generally in paralleland/or to overlap the path segments of the sixth layer 700 over much ofthe overall path lengths in a manner as shown in FIGS. 2C and 2E. Ifdesired: (a) at least 25% (and in some examples, at least 40%, at least50%, at least 60%, at least 75%, at least 85%, or even at least 90%) ofthe overall path length of the seventh layer 800 will overlap with pathsegments of the sixth layer 700 in the manner shown in FIGS. 2C and 2Eand/or (b) at least 25% (and in some examples, at least 40%, at least50%, at least 60%, at least 75%, at least 85%, or even at least 90%) ofthe overall path length of the sixth layer 700 will overlap with pathsegments of the seventh layer 800 in the manner shown in FIGS. 2C and2E. Thus, filaments of the seventh layer 800 will directly contactfilaments of the sixth layer 700 (at overlapping contact area 202) asthe seventh layer 800 is being extruded. Heat from the seventh layer 800while it is being extruded (and/or another heat source) causes theseventh filament path segments to fuse together with the sixth filamentpath segments at location(s) 202 where they contact one another (e.g.,the filament material of the seventh layer 800 may polymerize with andseamlessly join the filament material of the sixth layer 700). In thismanner, the sixth layer 700 of the upper or upper blank 1000 can befixedly joined to the seventh layer 800 of the upper or upper blank 1000in an adhesive free manner at contact location(s) 202.

As also evident from a comparison of FIG. 3L with FIGS. 3A, 3B, 3D, 3F,and 3H, the path segments of seventh layer 800 will substantiallyintersect the path segments of the first layer 300, the second layer350, the third layer 400, the fourth layer 500, and the fifth layer 600over a substantial portion of their overall paths. The intersecting pathsegments form generally diamond shapes, which can be seen in thecombined first through seventh layers 840 shown in FIG. 3M. The pathsegments of the seventh layer 800 may intersect the path segments of thefirst layer 300, the second layer 350, the third layer 400, the fourthlayer 500, and/or the fifth layer 600 at any desired angles, e.g., from5° to 175°, and in some examples, from 15° to 165°, from 25° to 155°,from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to 120°,from 65° to 90°, etc. In at least some examples of this invention: (a)the seventh path of the seventh layer 800 will overlap with one or moreof the first path of the first layer 300, the second path of the secondlayer 350, the third path of the third layer 400, the fourth path of thefourth layer 500, and/or the fifth path of the fifth layer 600 over lessthan 50% (and in some examples less than 40%, less than 30%, less than20%, or even less than 10%) of an overall length of the seventh path,and/or (b) the seventh path of the seventh layer 800 will overlap one ormore of the first path of the first layer 300, the second path of thesecond layer 350, the third path of the third layer 400, the fourth pathof the fourth layer 500, and/or the fifth path of the fifth layer 600over less than 50% (and in some examples less than 40%, less than 30%,less than 20%, or even less than 10%) of an overall length of therespective first path, second path, third path, fourth path, and/orfifth path.

Thus, filaments of the seventh layer 800 will directly contact filamentsof one or more of the first layer 300, the second layer 350, the thirdlayer 400, the fourth layer 500, and/or the fifth layer 600 (atintersecting contact area 202) as the seventh layer 800 is beingextruded. Heat from the seventh layer 800 as it is being extruded(and/or another heat source) causes the seventh filament path segmentsto fuse together with any one of or any combination of the firstfilament path segments, the second filament path segments, the thirdfilament path segments, the fourth filament path segments, and/or thefifth filament path segments at location(s) 202 where the seventhfilament path segments contact any one of or any combination of thefirst filament path segments, the second filament path segments, thethird filament path segments, the fourth filament path segments, and/orthe fifth filament path (e.g., the filament material of the seventhlayer 800 may polymerize with and seamlessly join the filament materialsof the first layer 300, the second layer 350, the third layer 400, thefourth layer 500, and/or the fifth layer 600).

In these manners, the seventh layer 800 of the upper or upper blank 1000can be fixedly joined to the first layer 300, the second layer 350, thethird layer 400, the fourth layer 500, the fifth layer 600, and/or thesixth layer 700 of the upper or upper blank 1000 in an adhesive freemanner at contact location(s) 202 to form the combined first throughseventh layers 840. The upper component or intermediate including thecombined first through seventh layers 840 constitutes a unitaryconstruction in which the first layer 300, the second layer 350, thethird layer 400, the fourth layer 500, the fifth layer 600, the sixthlayer 700, and the seventh layer 800 are fixed together only in anon-adhesive fused manner. The upper component or intermediate includingthe combined first through seventh layers 840 may consist essentiallyof, or even consist of, the first layer 300, the second layer 350, thethird layer 400, the fourth layer 500, the fifth layer 600, the sixthlayer 700, and the seventh layer 800.

In the seventh layer 800, the path segments in one area need not haveconstant spacing from directly adjacent path segments at other areas ofthe seventh layer 800. For example, as shown in FIG. 3L, the plural,non-intersecting, spaced apart path segments in the forefoot region 806of the seventh layer 800 are spaced closer together than are the plural,non-intersecting, spaced apart path segments in the midfoot region(s)804/808 and/or the plural, non-intersecting, spaced apart path segmentsin the forefoot region 806 and/or the midfoot region(s) 804/808 arespaced closer together than are the plural, non-intersecting, spacedapart path segments in the heel region(s) 802/810 of the seventh layer800.

After the seventh layer 800 is extruded (e.g., onto first layer 300,second layer 350, third layer 400, fourth layer 500, fifth layer 600,sixth layer 700, and/or substrate 106), an eighth layer 900 of theoverall upper or upper blank 1000 then may be applied to the combinedfirst through seventh layers 840. FIG. 3N shows the individual pathsegments of this example eighth layer 900, and FIG. 3O schematicallyshows the production of the eighth layer 900 onto the previouslyprepared combined first through seventh layers 840 to create thecombined first through eighth layers 1000 of the upper or upper blank1000. More specifically, FIG. 3N shows an eighth layer 900 formed of aneighth filament (e.g., having any of the filament features andcharacteristics described above) and formed by extruding an eighthmaterial into multiple path segments (e.g., having any of the pathand/or path segment features described above), e.g., by a soliddeposition modeling process. Optionally, this eighth layer 900 may beextruded as an eighth continuous path. In this illustrated example, theeighth path of the eighth filament (optionally as a continuous path)forms the following portions of the eighth layer 900: (a) an eighthlateral rear heel portion 902 (e.g., extending along and/or adjacent alateral side 902 s of the ankle/foot opening 914 of the eighth layer900); (b) an eighth lateral midfoot portion 904 (e.g., extending alongand/or adjacent a lateral side 904 s (or an inner edge) of an instepopening 912 of the eighth layer 900); (c) an eighth forefoot portion 906(e.g., which bridges from a lateral side to a medial side of the eighthlayer 900, forward of the midfoot portions); (d) an eighth medialmidfoot portion 908 (e.g., extending along and/or adjacent a medial side908 s (or an inner edge) of the instep opening 912 of the eighth layer900); and (e) an eighth medial rear heel portion 910 (e.g., extendingalong and/or adjacent a medial side 910 s of the ankle/foot opening 914of the eighth layer 900). The vertical dashed lines shown in FIG. 3Ngenerally define and break the eighth layer 900 into three portions: (a)a posterior third (containing the lateral rear heel portion 902 and themedial rear heel portion 910), (b) a central third (containing thelateral midfoot portion 904 and the medial midfoot portion 908), and (c)an anterior third (containing the forefoot portion 906). In at leastsome examples of this invention, the eighth layer 900 will consistessentially of, or even consist of, this filament structure (optionallyformed as a continuous path and/or a one piece construction). The whitespace visible in FIG. 3N for this example eighth layer 900 constitutesopen space between filament path segments (e.g., where one can seecompletely through the eighth layer 900).

While the path segments of the eighth layer 900 can be extruded in anydesired order without departing from this invention, in some examples ofthis invention, the outer perimeter (e.g., 900P) may be extruded first,and then the remainder of the eighth layer 900 can be extruded, e.g., ina “raster” like fashion, to fill in the area within the perimeter 900P.In this illustrated example, the extruded overall path of the eighthlayer 900 lays down the eighth filament over much of the overall surfacearea of the eighth layer 900 as eighth plural, non-intersecting, spacedapart path segments that extend in a substantially anterior-posteriordirection of the eighth layer 900. As shown in FIG. 3N, in the lateralrear heel portion 902, the forefoot portion 906, the medial midfootportion 908, and the medial rear heel portion 910, the eighth plural,non-intersecting path segments extend in a gently curved manner in adirection from the rear heel portion 902/910 forward. In the lateralmidfoot portion 904, however, at least some of the eighth plural,non-intersecting, spaced apart path segments extend in a serpentineconfiguration including at least two peaks (908P) and at least twovalleys (908V). The path segments in these various regions 902, 904,906, 908, 910 may have any of the features and/or options describedabove for the path segments shown in FIGS. 2A-2F.

As further shown in FIG. 3N, the eighth path of filament defines a firstinner edge at lateral instep opening edge 904 s, a first outer edge 904t at lateral midfoot region 904, a second inner edge at medial instepopening edge 908 s, and a second outer edge 908 t at medial midfootregion 908. An instep opening 912 for the eighth layer 900 is definedbetween the first inner edge at 904 s and the second inner edge at 908s. The eighth path of the filament in this example layer 900 includes:(a) first plural, non-intersecting, spaced apart path segments locatedbetween the first inner edge at 904 s and the first outer edge 904 t,wherein a plurality of the first plural, non-intersecting, spaced apartpath segments of the eighth path located between the first inner edge at904 s and the first outer edge 904 t extend in a serpentineconfiguration and have at least two peaks 908P and at least two valleys908V and (b) second plural, non-intersecting, spaced apart path segmentslocated between the second inner edge at 908 s and the second outer edge908 t, wherein the second, plural, non-intersecting, spaced apart pathsegments of the eighth continuous path are linear and/or curved withoutdefining plural peaks and valleys. The eighth layer 900 of FIG. 3N mayinclude at least 4 path segments, at least 6 path segments, at least 8path segments, at least 10 path segments, or even at least 12 pathsegments that extend substantially in parallel and/or have the notedserpentine configuration.

As evident from a comparison of FIGS. 3J, 3L, and 3N, the path segmentsof sixth layer 700, seventh layer 800, and eighth layer 900 extend overa substantial portion of their overall paths in a generally parallelmanner. Thus, the path segments of the eighth layer 900 may be extrudedgenerally in parallel and/or to overlap the path segments of the sixthlayer 700 and/or the seventh layer 800 over much of their overall pathlengths in a manner as shown in FIGS. 2C and 2E. If desired: (a) atleast 25% (and in some examples, at least 40%, at least 50%, at least60%, at least 75%, at least 85%, or even at least 90%) of the overallpath length of the eighth layer 900 will overlap with path segments ofat least one of the sixth layer 700 and/or the seventh layer 800 in themanner shown in FIGS. 2C and 2E and/or (b) at least 25% (and in someexamples, at least 40%, at least 50%, at least 60%, at least 75%, atleast 85%, or even at least 90%) of the overall path length of the sixthlayer 700 and/or the seventh layer 800 will overlap with path segmentsof the eighth layer 900 in the manner shown in FIGS. 2C and 2E. Thus,filaments of the eighth layer 900 will directly contact filaments of thesixth layer 700 and/or the seventh layer 800 (at overlapping contactarea 202) as the eighth layer 900 is being extruded. Heat from theeighth layer 900 while it is being extruded (and/or another heat source)causes the eighth filament path segments to fuse together with either orboth of the sixth filament path segments and/or the seventh filamentpath segments at location(s) 202 where the eighth filament path segmentscontact either or both of the sixth filament path segments and/or theseventh filament path segments (e.g., the filament material of theeighth layer 900 may polymerize with and seamlessly join the filamentmaterial of the sixth layer 700 and/or the seventh layer 800). In thismanner, the sixth layer 700 and/or seventh layer 800 of the upper orupper blank 1000 can be fixedly joined to the eighth layer 900 of theupper or upper blank 1000 in an adhesive free manner at contactlocation(s) 202.

As also evident from a comparison of FIG. 3N with FIGS. 3A, 3B, 3D, 3F,and 3H, the path segments of eighth layer 900 will substantiallyintersect the path segments of the first layer 300, the second layer350, the third layer 400, the fourth layer 500, and the fifth layer 600over a substantial portion of their overall paths. The intersecting pathsegments form generally diamond shapes, which can be seen in thecombined first through eighth layers 1000 shown in FIGS. 3O and 3P. Thepath segments of the eighth layer 900 may intersect the path segments ofthe first layer 300, the second layer 350, the third layer 400, thefourth layer 500, and/or the fifth layer 600 at any desired angles,e.g., from 5° to 175°, and in some examples, from 15° to 165°, from 25°to 155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60°to 120°, from 65° to 90°, etc. In at least some examples of thisinvention: (a) the eighth path of the eighth layer 900 will overlap withone or more of the first path of the first layer 300, the second path ofthe second layer 350, the third path of the third layer 400, the fourthpath of the fourth layer 500, and/or the fifth path of the fifth layer600 over less than 50% (and in some examples less than 40%, less than30%, less than 20%, or even less than 10%) of an overall length of theeighth path, and/or (b) the eighth path of the eighth layer 900 willoverlap one or more of the first path of the first layer 300, the secondpath of the second layer 350, the third path of the third layer 400, thefourth path of the fourth layer 500, and/or the fifth path of the fifthlayer 600 over less than 50% (and in some examples less than 40%, lessthan 30%, less than 20%, or even less than 10%) of an overall length ofthe respective first path, second path, third path, fourth path, and/orfifth path.

Thus, filaments of the eighth layer 900 will directly contact filamentsof one or more of the first layer 300, the second layer 350, the thirdlayer 400, the fourth layer 500, and/or the fifth layer 600 (atintersecting contact area 202) as the eighth layer 900 is beingextruded. Heat from the eighth layer 900 while it is being extruded(and/or another heat source) causes the eighth filament path segments tofuse together with any one of or any combination of the first filamentpath segments, the second filament path segments, the third filamentpath segments, the fourth filament path segments, and/or the fifthfilament path segments at location(s) 202 where the eighth filament pathsegments contact any one of or any combination of the first filamentpath segments, the second filament path segments, the third filamentpath segments, the fourth filament path segments, and/or the fifthfilament path segments (e.g., the filament material of the eighth layer900 may polymerize with and seamlessly join the filament materials ofthe first layer 300, the second layer 350, the third layer 400, thefourth layer 500, and/or the fifth layer 600).

In these manners, the eighth layer 900 of the upper or upper blank 1000can be fixedly joined to the first layer 300, the second layer 350, thethird layer 400, the fourth layer 500, the fifth layer 600, the sixthlayer 700, and/or the seventh layer 800 of the upper or upper blank 1000in an adhesive free manner at contact location(s) 202 to form thecombined first through eighth layers 1000. The upper component orintermediate including the combined first through eighth layers 1000constitutes a unitary construction in which the first layer 300, thesecond layer 350, the third layer 400, the fourth layer 500, the fifthlayer 600, the sixth layer 700, the seventh layer 800, and the eighthlayer 900 are fixed together only in a non-adhesive fused manner. Theupper component or upper blank 1000 may consist essentially of, or evenconsist of, the first layer 300, the second layer 350, the third layer400, the fourth layer 500, the fifth layer 600, the sixth layer 700, theseventh layer 800, and the eighth layer 900.

In the eighth layer 900, the path segments in one area need not haveconstant spacing from directly adjacent path segments at other areas ofthe eighth layer 900. For example, as shown in FIG. 3N, the plural,non-intersecting, spaced apart path segments in the forefoot region 906of the eighth layer 900 are spaced closer together than are the plural,non-intersecting, spaced apart path segments in the midfoot region(s)904/908 and/or the plural, non-intersecting, spaced apart path segmentsin the forefoot region 906 and/or the midfoot region(s) 904/908 arespaced closer together than are the plural, non-intersecting, spacedapart path segments in the heel region(s) 902/910 of the eighth layer900.

After all desired layers of the upper or upper blank 1000 are formed,the extruded and fused layers form a fused upper component (e.g., anupper blank 1000). Then, the fused upper component 1000 may be removedfrom the base substrate 106 onto which it was extruded, optionallytrimmed (e.g., around its perimeter edges, if needed) or otherwiseprocessed (e.g., coated, painted, etc.), optionally engaged with anotherupper component, and/or incorporated into a footwear structure, as willbe explained in more detail below. As described above, if desired, thesurface 106 s of the substrate 106 onto which the layer(s) of filamentare extruded may be smooth or otherwise textured. The surface (e.g.,individual filaments) of the upper blank 1000 that contacted thesubstrate 106 surface 106 s then may take on the smoothness (ortextured) characteristics of the substrate 106 surface 106 s on which itcontacts and is formed. Thus, in some examples of this invention, onesurface (e.g., the inner surface or bottom surface) of the upper blank1000 may be smooth or textured to correspond to texture on the surface106 s of the substrate 106 while the opposite surface (e.g., the outersurface or top surface) of the upper blank 1000 may have texturecorresponding to the multiple overlapping layers of filament.

FIGS. 3Q to 3W provide enlarged views of portions of the upper blank1000 at areas A-G shown in FIG. 3P to show more details of these examplestructures. FIGS. 3Q and 3R provide enlarged views of the upper blank1000 at the lateral rear heel portion 1002 and the medial rear heelportion 1010 (areas A and B, respectively); FIGS. 3S and 3T provideenlarged views of the upper blank 1000 at the lateral midfoot portion1004 and the medial midfoot portion 1008 (areas C and D, respectively);and FIGS. 3U, 3V, and 3W provide enlarged views of the upper blank 1000at the lateral forefoot portion, the medial forefoot portion, and theextreme forefoot portion (areas E, F, and G, respectively).

As shown in FIG. 3Q, the filaments of the first layer 300 and the secondlayer 350 at this location of the upper blank 1000 (which may besubstantially parallel and/or overlapping over much of their lengths)generally extend in a direction between the ankle opening 1014 and thebottom perimeter edge of the upper blank 1000 (e.g., in a medio-lateraldirection). The filaments of the third layer 400, the fourth layer 500,and the fifth layer 600 generally curve (and are substantially inparallel and/or overlapping) and extend in an anterior-posteriordirection. Similarly, the filaments of the sixth layer 700, the seventhlayer 800, and the eighth layer 900 generally curve (and aresubstantially in parallel and/or overlapping) and extend in ananterior-posterior direction. The filaments of the first layer 300 andsecond layer 350 intersect the filaments of the third layer 400, fourthlayer 500, and fifth layer 600 and form generally parallelogram ordiamond shapes (e.g., with angles between 60° and 120°). Similarly, thefilaments of the first layer 300 and second layer 350 intersect thefilaments of the sixth layer 700, seventh layer 800, and eighth layer900 and form generally parallelogram or diamond shapes (e.g., withangles between 60° and 120°). The filaments of the third layer 400,fourth layer 500, and fifth layer 600 intersect the filaments of thesixth layer 700, seventh layer 800, and eighth layer 900 and formgenerally parallelogram or diamond shapes (e.g., with two angles between5° and 60° and two angles between 120° and 175°). When formed asparallelogram and/or diamond shapes, a long axis of theparallelogram/diamond shapes formed by the filaments of layers400/500/600 and the filaments of layers 700/800/900 may extend ingenerally an anterior-posterior direction of the upper blank 1000 (e.g.,as shown by diamond DIA highlighted in FIG. 3Q).

As shown in FIG. 3R, the filaments of the first layer 300 and the secondlayer 350 at this location of the upper blank 1000 (which may besubstantially parallel and/or overlapping over much of their lengths)generally extend in a direction between the ankle opening 1014 and thebottom perimeter edge of the upper blank 1000 (e.g., in a medio-lateraldirection). The filaments of the third layer 400, the fourth layer 500,and the fifth layer 600 generally curve (and are substantially inparallel and/or overlapping) and extend in an anterior-posteriordirection. Similarly, the filaments of the sixth layer 700, the seventhlayer 800, and the eighth layer 900 generally curve (and aresubstantially in parallel and/or overlapping) and extend in ananterior-posterior direction. The filaments of the first layer 300 andsecond layer 350 intersect the filaments of the third layer 400, fourthlayer 500, and fifth layer 600 and form a generally parallelogram ordiamond shaped pattern (e.g., with angles between 60° and 120°).Similarly, the filaments of the first layer 300 and second layer 350intersect the filaments of the sixth layer 700, seventh layer 800, andeighth layer 900 and form generally parallelogram or diamond shapes(e.g., with angles between 60° and 120°). The filaments of the thirdlayer 400, fourth layer 500, and fifth layer 600 intersect the filamentsof the sixth layer 700, seventh layer 800, and eighth layer 900 and formgenerally parallelogram or diamond shapes (e.g., with two angles between5° and 60° and two angles between 120° and 175°). When formed asparallelogram and/or diamond shapes, a long axis of theparallelogram/diamond shapes formed by the filaments of layers400/500/600 and the filaments of layers 700/800/900 may extend ingenerally an anterior-posterior direction of the upper blank 1000 (e.g.,as shown by diamond DIA highlighted in FIG. 3R).

As shown in FIG. 3S, the filaments of the first layer 300 and the secondlayer 350 at this location of the upper blank 1000 (which may besubstantially parallel and/or overlapping over much of their lengths)generally extend in a direction between the instep opening 1012 and thebottom perimeter edge of the upper blank 1000 (e.g., in a medio-lateraldirection). The filaments of the third layer 400, the fourth layer 500,and the fifth layer 600 generally curve (and are substantially inparallel and/or overlapping) and extend in an anterior-posteriordirection. The filaments of the sixth layer 700, the seventh layer 800,and the eighth layer 900 in this area of the upper blank 1000 form theserpentine pattern described above (and are substantially in paralleland/or overlapping), and generally extend in an anterior-posteriordirection. The intersecting filaments of the various layers may have anyof the angular properties described above in conjunction with FIGS. 3Qand 3R. At this particular area of the upper blank 1000, theintersecting filaments define some more “square” or rectangular openingsthrough the upper blank 1000.

As shown in FIG. 3T, the filaments of the first layer 300 and the secondlayer 350 at this location of the upper blank 1000 (which may besubstantially parallel and/or overlapping over much of their lengths)generally extend in a direction between the instep opening 1012 and thebottom perimeter edge of the upper blank 1000 (e.g., in a medio-lateraldirection). The filaments of the third layer 400, the fourth layer 500,and the fifth layer 600 in this area of the upper blank 1000 form theserpentine pattern described above (and are substantially in paralleland/or overlapping), and generally extend in an anterior-posteriordirection. The filaments of the sixth layer 700, the seventh layer 800,and the eighth layer 900 generally curve (and are substantially inparallel and/or overlapping) and extend in an anterior-posteriordirection. The intersecting filaments of the various layers may have anyof the angular properties described above in conjunction with FIGS. 3Qand 3R. At this particular area of the upper blank 1000, theintersecting filaments define some more “square” or rectangular openingsthrough the upper blank 1000.

As shown in FIG. 3U, the filaments of the first layer 300 and the secondlayer 350 at this location of the upper blank 1000 (which may besubstantially parallel and/or overlapping over much of their lengths)generally extend in a medio-lateral direction across the upper blank1000 (from the medial side toward the lateral side). The filaments ofthe third layer 400, the fourth layer 500, and the fifth layer 600generally curve (and are substantially in parallel and/or overlapping)and extend in an anterior-posterior direction. Similarly, the filamentsof the sixth layer 700, the seventh layer 800, and the eighth layer 900generally curve (and are substantially in parallel and/or overlapping)and extend in an anterior-posterior direction. The filaments of thefirst layer 300 and second layer 350 intersect the filaments of thethird layer 400, fourth layer 500, and fifth layer 600 and formgenerally parallelogram or diamond shapes (e.g., with angles between 60°and 120°). Similarly, the filaments of the first layer 300 and secondlayer 350 intersect the filaments of the sixth layer 700, seventh layer800, and eighth layer 900 and form generally parallelogram or diamondshapes (e.g., with angles between 60° and 120°). The filaments of thethird layer 400, fourth layer 500, and fifth layer 600 intersect thefilaments of the sixth layer 700, seventh layer 800, and eighth layer900 and form generally parallelogram or diamond shapes (e.g., with twoangles between 5° and 60° and two angles between 120° and 175°). Whenformed as parallelogram and/or diamond shapes, a long axis of theparallelogram/diamond shapes formed by the filaments of layers400/500/600 and the filaments of layers 700/800/900 may extend ingenerally an anterior-posterior direction of the upper blank 1000 (e.g.,as shown by diamond DIA highlighted in FIG. 3U).

As shown in FIG. 3V, the filaments of the first layer 300 and the secondlayer 350 at this location of the upper blank 1000 (which may besubstantially parallel and/or overlapping over much of their lengths)generally extend in a medio-lateral direction across the upper blank1000 (from the medial side toward the lateral side). The filaments ofthe third layer 400, the fourth layer 500, and the fifth layer 600generally curve (and are substantially in parallel and/or overlapping)and extend in an anterior-posterior direction. Similarly, the filamentsof the sixth layer 700, the seventh layer 800, and the eighth layer 900generally curve (and are substantially in parallel and/or overlapping)and extend in an anterior-posterior direction. The filaments of thefirst layer 300 and second layer 350 intersect the filaments of thethird layer 400, fourth layer 500, and fifth layer 600 and formgenerally parallelogram or diamond shapes (e.g., with angles between 60°and 120°). Similarly, the filaments of the first layer 300 and secondlayer 350 intersect the filaments of the sixth layer 700, seventh layer800, and eighth layer 900 and form generally parallelogram or diamondshapes (e.g., with angles between 60° and 120°). The filaments of thethird layer 400, fourth layer 500, and fifth layer 600 intersect thefilaments of the sixth layer 700, seventh layer 800, and eighth layer900 and form generally parallelogram or diamond shapes pattern (e.g.,with two angles between 5° and 60° and two angles between 120° and175°). When formed as parallelogram and/or diamond shapes, a long axisof the parallelogram/diamond shapes formed by the filaments of layers400/500/600 and the filaments of layers 700/800/900 may extend ingenerally an anterior-posterior direction of the upper blank 1000 (e.g.,as shown by diamond DIA highlighted in FIG. 3V).

As shown in FIG. 3W, the filaments of the first layer 300 and the secondlayer 350 at this location of the upper blank 1000 (which may besubstantially parallel and/or overlapping over much of their lengths)generally extend in a medio-lateral direction across the upper blank1000 (from the medial side toward the lateral side). The filaments ofthe third layer 400, the fourth layer 500, and the fifth layer 600generally curve (and are substantially in parallel and/or overlapping)and extend in an anterior-posterior direction. Similarly, the filamentsof the sixth layer 700, the seventh layer 800, and the eighth layer 900generally curve (and are substantially in parallel and/or overlapping)and extend in an anterior-posterior direction. The filaments of thefirst layer 300 and second layer 350 intersect the filaments of thethird layer 400, fourth layer 500, and fifth layer 600 and formgenerally parallelogram or diamond shapes (e.g., with angles between 60°and 120°). Similarly, the filaments of the first layer 300 and secondlayer 350 intersect the filaments of the sixth layer 700, seventh layer800, and eighth layer 900 and form generally parallelogram or diamondshapes (e.g., with angles between 60° and 120°). The filaments of thethird layer 400, fourth layer 500, and fifth layer 600 intersect thefilaments of the sixth layer 700, seventh layer 800, and eighth layer900 and form generally parallelogram or diamond shapes (e.g., with twoangles between 5° and 60° and two angles between 120° and 175°). Whenformed as parallelogram and/or diamond shapes, a long axis of theparallelogram/diamond shapes formed by the filaments of layers400/500/600 and the filaments of layers 700/800/900 may extend ingenerally an anterior-posterior direction of the upper blank 1000 (e.g.,as shown by diamond DIA highlighted in FIG. 3W).

As evident from a comparison of FIGS. 3Q-3V with 3W, the spacingsbetween directly adjacent filaments in a given layer generally becomesmaller at the forefoot area of this example upper blank 1000 ascompared to the spacings between directly adjacent filaments in the samelayer at the rear heel and/or midfoot portions of the upper blank 1000.Also, as shown in these figures, the diamond shaped openings formed byintersections between (a) the filaments of the third layer 400, fourthlayer 500, and fifth layer 600 and (b) the filaments of the sixth layer700, seventh layer 800, and eighth layer 900 become smaller toward theforefoot area of the upper blank 1000 as compared to the correspondingdiamond shaped openings provided at the rear heel and/or midfootportions of the upper blank 1000. These features provide improvedsupport, durability, lock-down, and less stretchability at the forefootarea of the upper blank 1000 as compared to at least some other areas.As further evident from the enlarged views of FIGS. 3Q-3W, much of thespace within the perimeter of the upper or upper blank constitutes openspace between intersections of the filaments in the layers of the upperor upper blank 1000. In at least some examples of this invention, theupper or upper blank 1000 may constitute at least 15% open space betweenfilaments of the various layers, and in some examples, at least 25%, atleast 30%, at least 40%, or even at least 50% open space may be presentbetween filaments in the upper or upper blank 1000.

Many variations in the upper or upper blank 1000 structure and/orindividual upper layers of filament are possible without departing fromthis invention. As some examples, an upper or upper blank 1000 couldinclude more or fewer upper layers than the eight layers described above(e.g., from 2 to 24 layers, and in some examples, from 3 to 20 layers,from 4 to 16 layers, from 5 to 12 layers, etc.). As additional oralternative examples, the layering order of the filament layersdescribed above could be changed in some examples of this invention.Additionally or alternatively, while FIGS. 3D, 3F, and 3H show theserpentine configurations formed at the medial midfoot portions of thethird layer 400, the fourth layer 500, and the fifth layer 600,respectively, and FIGS. 3J, 3L, and 3N show the serpentineconfigurations formed at the lateral midfoot portions of the sixth layer700, the seventh layer 800, and the eighth layer 900, respectively, anupper or upper blank in accordance with some examples of this inventionmay include more of fewer of this same type of “serpentine”configurations, e.g., in one or more of the forefoot area, the rear heelareas, etc. More or fewer layers of an upper blank 1000 also may includethis type of “serpentine” configuration. The curved and serpentineconfigurations of the filament layers provide enhanced flexibility.

The filament materials provided in the various layers of a single upperor upper blank 1000 may be the same or different without departing fromthis invention. As some more specific examples, the upper or upper blankand/or the individual layers thereof may have one or more of thefollowing properties or characteristics: (a) the filament materials onall layers of an upper or upper blank may be the same material; (b) thefilament material in one layer of an upper or upper blank may differfrom the filament material in one or more other layers of the upper orupper blank; (c) the filament material may be different in each layer ofan upper or upper blank; (d) the filaments on all layers of an upper orupper blank may be the same color; (e) the filament color in one layerof an upper or upper blank may differ from the filament color in one ormore other layers of the upper or upper blank; (f) the filament colorsmay be different in each layer of an upper or upper blank; (g) thefilament in one or more layers of an upper or upper blank may be madefrom a transparent or translucent material; (h) the filament in one ormore layers of the upper or upper blank (and optionally in each layer ofthe upper or upper blank) may be made from a thermoplastic material(e.g., a thermoplastic polyurethane material); (i) the filament in oneor more layers of the upper or upper blank (and optionally in each layerof the upper or upper blank) may be made from a material that does notsubstantially absorb water; (j) the filament in one or more layers ofthe upper or upper blank (and optionally in each layer of the upper orupper blank) may be made from a hydrophobic material; (k) the filamentin one or more layers of the upper or upper blank (and optionally ineach layer of the upper or upper blank) may be made from a materialcapable of fusing to material(s) of the other layers, e.g., in anadhesive free manner, such as via a solid deposition modeling technique;(1) the filament materials on all layers of an upper or upper blank mayhave the same diameter, width, and/or thickness (or other dimensions);and/or (m) the filament material in one layer of an upper or upper blankmay differ in diameter, width, and/or thickness (or other dimensions)from the filament material in one or more other layers of the upper orupper blank. In some examples of this invention, the upper or upperblank (e.g., two or more layers thereof cooperatively) may produce amoiré effect, e.g., as shown in FIGS. 1 and 3A-3P.

As described above, in at least some examples of this invention, one ormore of the various upper layers (e.g., layers 300, 350, 400, 500, 600,700, 800, and/or 900) may be formed as a continuous path of extrudedfilament. For example, in some examples of this invention, the entireupper layer (e.g., as shown in each of one or more of FIG. 3A (firstlayer 300), FIG. 3B (second layer 350), FIG. 3D (third layer 400), FIG.3F (fourth layer 500), FIG. 3H (fifth layer 600), FIG. 3J (sixth layer700), FIG. 3L (seventh layer 800), and FIG. 3N (eighth layer 900)) maybe formed by beginning extrusion at one location of the individual upperlayer and extruding material continuously (including through allnecessary turns of the extruder nozzle 104/head) until the entire layeris completely extruded (e.g., into the form shown in one or more ofFIGS. 3A, 3B, 3D, 3F, 3H, 3J, 3L, and 3N). This type of continuousextrusion path (with one start and one stop in extruding an entirelayer), however, is not a requirement. Rather, in at least some examplesof this invention, an individual upper layer (e.g., like those shown inFIGS. 3A, 3B, 3D, 3F, 3H, 3J, 3L, and 3N) may be formed in adiscontinuous manner (e.g., with two or more pairs of extrusionstart/stop actions per individual layer). The extrusion nozzle 104/headmay be moved between the extrusion starts and stops (while extrusion isstopped) to another desired location of the upper layer so that theextrusion path segments of the layer can begin/end at any desiredlocations.

Further, FIGS. 3A-3P show that each individual layer 300, 350, 400, 500,600, 700, 800, 900 in this illustrated upper or upper blank 1000includes individual path segments throughout each of the lateral rearheel portion, lateral midfoot portion, forefoot portion, medial midfootportion, and medial rear heel portion. This is not a requirement.Rather, if desired, in accordance with some examples of this invention,an individual upper layer (e.g., one or more of 300, 350, 400, 500, 600,700, 800, and/or 900) need not extend into and/or throughout all of thenoted regions. As some more specific examples, if desired: (a) one ormore layers of the upper may be present in only the forefoot region ofthe overall upper; (b) one or more layers may be present in only thelateral midfoot region and/or medial midfoot region of the overallupper; (c) one or more layers may be present in the forefoot region andone or both of the lateral midfoot region and/or medial midfoot regionof the overall upper; (d) one or more layers may be omitted at one orboth of the lateral rear heel region and/or the medial rear heel region;(e) only a small amount of filament may be present in some portions orregions of an individual layer; etc. Selective inclusion of filament atless than all regions of an upper layer can allow one to selectivelycontrol properties in that region of the overall upper or upper blank(e.g., control breathability, stretchability, permeability, lock down,etc.). When one or more layers are omitted in an individual area orregion, the layers of filament that are included in that individual areaor region need not be extruded consecutively in the overall upperproduction process. For example, if desired, an individual area orregion of an upper or upper blank may include the first layer 300, thesecond layer 350, the fourth layer 500, the sixth layer 700, and theseventh layer 800 (or any desired number and/or combination of layers,including layers having different paths from the specific examples shownin the figures).

FIGS. 3A-3P further show an example with upper layers laid down asfilaments in a specific order, i.e., layer 300, then layer 350, thenlayer 400, then layer 500, then layer 600, then layer 700, then layer800, then layer 900. The order in which layers are put down caninfluence the characteristics and/or properties of the overall upper orupper blank 1000. For example, if layers with larger filament spacingsare laid down closer to the upper interior and layers with smallerfilament spacings are laid down closer to the upper exterior, this mayenhance the overall upper’s ability to shed water (or other materials)and/or resist introduction of water (or other materials) inside and/orwithin the upper as compared to an upper with the same layers formed ina different order with larger filament spacings located closer to theupper exterior. Changing layer orders also may affect zonal or overallperformance of the upper (e.g., affect lockdown, directional stretch,breathability, permeability, etc.) By changing the layer orders, theintersections of the different layers may be altered and/or changed inlocations, and thus the fusion of one layer to the other layers may bealtered and/or changed to different locations and/or positions. Thesechanges may affect overall properties, performance, and/or feel of theupper (e.g., lockdown, directional stretch, breathability, permeability,etc.).

As mentioned above, if desired, the upper blank 1000 or an uppercomponent built from one or more layers of extruded filaments of thetypes described above may be engaged with one or more other uppercomponents. FIGS. 4A through 4C illustrate examples in which thefilament(s) 1102, 1104, 1106, 1108 of one or more layers of an extrudedfilament based upper component 1100 are engaged with another uppercomponent 1110, e.g., by an adhesive or cement 1112. The extrudedfilament based upper component 1100 may be made of one or more layers ofextruded filament, e.g., including one of more layers, including any oneor more of the various layers 300, 350, 400, 500, 600, 700, 800, and/or900 described above. The upper component 1110 may be any desired type ofupper component, including upper components as conventionally known andused in the footwear arts, such as fabrics, textiles, elastic materials,knitted components, woven components, leathers (natural or synthetic),thermoplastic materials, thermoplastic polyurethanes, other polymermaterials, etc. The extruded filament based upper component 1100: (a)may be located outside the other upper component 1110 toward thefootwear exterior and away from the wearer’s foot (FIG. 4A); (b) may belocated inside the other upper component 1110 toward the footwearinterior and closer to (and optionally adjacent or in contact with) thewearer’s foot (FIG. 4B); and/or (c) may be both inside and outside theother upper component 1110 (FIG. 4C). The additional upper component(s)1110 may provide additional support at desired areas (e.g., a heelcounter, a toe box, structural support, shape support, lace engagingsupport along the instep opening 1012, structure for engaging a solecomponent, etc.); a soft foot contact surface (e.g., around the ankleopening 1014, as a “tongue” member across the instep opening 1012,etc.); support for engaging another footwear component; etc. Thecombined upper components 1100/1110 may be incorporated into an overallfootwear structure, as will be described in more detail below.

FIGS. 5A through 5C, however, illustrate engagement of an extrudedfilament based upper component 1100 with another upper component 1120 inan adhesive free manner, by fusing (or fuse bonding) the filament(s) inthe upper component 1100 directly with the material of the other uppercomponent 1120. Such combined upper components 1100/1120 may include:(a) a first upper component 1100 that includes at least a first layerformed to include a first material as a first filament 1102 (fourfilaments 1102, 1104, 1106, and 1108 are shown in FIGS. 5A-5C),optionally including first plural, non-intersecting, spaced apart pathsegments of the filament, wherein the first extruded filament has awidth dimension of less than 3 mm wide (and in some examples, less than2 mm wide, less than 1.5 mm wide, less than 1 mm wide, or even less than0.75 mm wide); and (b) a second upper component 1120 including a fabricelement (e.g., of any of the types described above for upper component1110, such as fabrics, textiles, elastic materials, thermoplasticmaterials, etc.) formed at least in part of a fusible material. Theextruded filament based upper component 1100 may be made of one or morelayers of extruded filament, e.g., including one of more layers likelayers 300, 350, 400, 500, 600, 700, 800, and/or 900 described above. Insuch structures, the fusible material of the second upper component 1120is fused to the filaments 1102, 1104, 1106, and/or 1108 of the firstupper component 1100. If necessary or desired, heat and/or pressure maybe applied to the combined upper components 1100/1120 to fuse thefilament containing upper component 1100 to the fabric element uppercomponent 1120. The fusing between components 1100 and 1120 may be aresult of the material of one or more filaments 1102-1108 polymerizingwith and seamlessly joining the fusible material of the fabric element1120.

FIGS. 5A through 5C illustrate examples in which the filament(s) 1102,1104, 1106, 1108 of one or more layers of an extruded filament uppercomponent 1100 are engaged with an upper component 1120 that includes afusible material as part of a fabric element. The extruded filamentupper component 1100: (a) may be located outside the other uppercomponent 1120 toward the footwear exterior and away from the wearer’sfoot (FIG. 5A); (b) may be located inside the other upper component 1120toward the footwear interior and closer to (and optionally adjacent orin contact with) the wearer’s foot (FIG. 5B); and/or (c) may be bothinside and outside the other upper component 1120 (FIG. 5C). Theadditional upper component(s) 1120 may provide additional support atdesired areas (e.g., a heel counter, a toe box, structural support,shape support, lace engaging support along the instep opening 1012,structure for engaging a sole component, etc.); a soft foot contactsurface (e.g., around the ankle opening 1014, as a “tongue” memberacross the instep opening 1012, etc.); structure for engaging anotherfootwear component; etc. The combined upper components 1100/1120 may beincorporated into an overall footwear structure, as will be described inmore detail below.

FIGS. 5D through 5F provide examples of manners in which a fusiblematerial may be incorporated into a fabric element 1120. As one example,as shown in FIG. 5D, a fabric element 1120 may be formed as a woven,knitted, or unwoven structure in which at least one strand (e.g., yarn)of the fabric element 1120 is formed of a fusible material compatible tofuse with the material of one or more of the filaments of uppercomponent 1100. In FIG. 5D, the yarn 1122 of one color is a traditionalfabric material (e.g., made from a polyester, cotton, elastomericmaterial, etc.) and the yarn 1124 of the other color is made from thefusible material of the types described above for the fusible materialin the filaments, such as a thermoplastic polyurethane material or otherthermoplastic material. In this arrangement, the yarn 1124 can directlyfuse to the filament(s) 1102, 1104, 1106, 1108 of the filament basedupper component 1100.

As another option, as shown in FIG. 5E, a fabric element 1120 may beformed as a woven, knitted, or unwoven structure that includes at leastone yarn of the fabric element structure 1120 formed of: (a) a strand1132 made of a traditional fabric material (e.g., made from a polyester,cotton, elastomeric material, etc.) intertwined with (b) a strand 1134made from the fusible material of the types described above for thefusible material in the filaments, such as a thermoplastic polyurethanematerial or other thermoplastic material. In this arrangement, thefusible yarn strand 1134 can directly fuse to the filament(s) 1102,1104, 1106, 1108 of the filament based upper component 1100.

As yet another option, FIG. 5F provides a cross sectional view of a yarnor strand that may be used to make a fabric element 1120, e.g., as awoven, knitted, or unwoven structure. This strand or yarn is formed as acoaxial element over at least a portion of its axial length, including:(a) an inner core 1142 made of a traditional fabric material (e.g., madefrom a polyester, cotton, elastomeric material, etc.) coated (e.g.,co-extruded or otherwise formed) with (b) an outer cover 1144 made fromthe fusible material of the types described above for the fusiblematerial in the filaments, such as a thermoplastic polyurethane materialor other thermoplastic material. In this arrangement, the fusible outercover 1144 can directly fuse to the filament(s) 1102, 1104, 1106, 1108of the filament based upper component 1100.

FIGS. 6A through 6E illustrate an example of a manner in which aconventional fabric element (or other footwear component) 1110 and/or afabric element 1120 including a fusible material (e.g., of the typesdescribed above in conjunction with FIGS. 5D-5F) can be engaged with amulti-layered fusible upper component 1100 (e.g., of the types describedabove in conjunction with FIGS. 1A-3W). First, an upper blankintermediate 1200 can be made including one or more layers of extrudedfilament formed as described above (e.g., by a solid deposition modelingtechnique, as a continuous path, with plural, non-intersecting pathsegments, etc.). FIG. 6A shows an upper blank intermediate 1200 formedto include the first four layers 300, 350, 400, 500 of filament asdescribed above, e.g., which can be formed in the same manners asdescribed above. Any desired number of filament layers, having anydesired filament paths and arrangements, may be provided as upper blankintermediate 1200 without departing from this invention (including oneor more filament based layers and/or any individual layer and/orcombination of layers described above).

Once the desired upper blank intermediate 1200 has been preparedincluding one or more filament layers (e.g., by extrusion, soliddeposition modeling, etc.) on the extruder substrate 106, a releaseliner 1202 may be applied, e.g., to cover a portion of the top surfaceof the upper blank intermediate 1200 (e.g., a portion of the first layerextending inwardly from a peripheral edge of the first layer may becovered with the release liner 1202, such as a portion around one orboth sides of the instep opening, a portion around one or both sides ofthe ankle opening, a portion around the bottom edge where the upper willmeet a sole structure, etc.). The release liner 1202 may be made frompaper, plastic, or any type of material, provided that the release liner1202 does not become permanently fixed to the filament material(s) to beincluded in the upper component in the steps to follow.

With the release liner 1202 in place, one or more additional layers offilament may be extruded to form one or more additional layers of theupper component. For example, as shown in FIG. 6B, the fifth layer 600,sixth layer 700, seventh layer 800, and/or the eighth layer 900described above may be extruded onto the release liner 1202 and theupper intermediate 1200 (which may include the first layer 300, secondlayer 350, third layer 400, and/or fourth layer 500 described above). Inthis illustrated example, one or more additional materials are extrudedto form one or more additional layers of extruded filament, optionallyincluding additional plural, non-intersecting, spaced apart pathsegments in the individual layer(s). The additional extruded filament(s)may have any of the dimensional and/or other filament characteristicsdescribed above. The additional layer extruding step(s) of this examplemay include: (a) applying a first portion of the additional filamentlayer(s) to the release liner 1202 such that the release liner 1202extends between a first portion of the previously extruded filamentlayer(s) (in upper intermediate 1200) and the first portion of theadditional layer(s) of filament and (b) fusing a second portion of theadditional layer(s) of filament to a second portion of the previouslyextruded filament layer(s) (in upper intermediate 1200) at locationswhere the more recently extruded filament layer(s) contact thepreviously extruded filament layers. In this manner, the additionalfilament layer(s) applied after the release liner 1202 is positionedwill join to (in an adhesive free manner) to the previously extrudedfilament layer(s) at areas away from the release liner 1202 to provide aunitary upper component (e.g., an overall upper component, like upperblank 1000 described above).

Once all of the desired additional filament layers are extruded andjoined to the previously extruded filament layers of upper intermediate1200, a combined upper component 1210 and release liner 1202 combinationis present, e.g., as shown in FIG. 6C. At this time, one or more of theupper component 1210 filament layers are located below a bottom surfaceof the release liner 1202 and one or more of the upper component 1210filament layers are located above a top surface of the release liner1202. At this time, the upper component 1210 and release liner 1202 canbe removed from the extruder substrate 106, and the release liner 1202can be removed from its location between the first portion of the lowerfilament layer(s) of the upper component 1210 (e.g., layers 300, 350,400, 500) and the first portion of the upper filament layer(s) of theupper component 1210 (e.g., layers 600, 700, 800, 900). Because of theprevious presence of the release liner 1202, the first portion of thelower filament layer(s) of the upper component 1210 (e.g., layers 300,350, 400, 500) will remain unfixed to the first portion of the upperfilament layer(s) of the upper component 1210 (e.g., layers 600, 700,800, 900) at the location where the release liner 1202 was present(although all layers 300-900 may be fixed together at the “secondportions” thereof, where the release liner 1202 was not present). Inother words, the presence and removal of the release liner 1202 forms a“pocket” between layers of the upper component 1210.

At this time, as shown in FIG. 6D, another upper component (e.g., fabriccomponent 1110, 1120 like those described above) may be placed into the“pocket” formed between layers of the upper component 1210 where therelease liner 1202 was removed. The upper component 1110 could beengaged with the upper component 1210 via adhesives, as described abovein conjunction with FIG. 4C. Alternatively, when upper component 1120includes a fusible material (e.g., a fabric element of the typesdescribed above in conjunction with FIGS. 5D-5F), then upper component1120 can be engaged with the upper component 1210 in an adhesive freemanner, e.g., by fusing the fusible material of the upper component 1120with the extruded filament material(s) of the upper component 1210. Thisaction can place and fix the upper component 1120 between individuallayers of the upper component 1210, e.g., as shown in the cross sectionof FIG. 5C. If needed, this fusing step can include, for example,applying heat and/or pressure to the combined upper component 1120/uppercomponent 1210, e.g., in the form shown in FIG. 6E. If necessary, theupper component 1120 (and/or 1210) can be trimmed, combined with otherupper components, and/or otherwise processed, if necessary, e.g., inpreparation for incorporation into a footwear structure. While FIGS. 6Ato 6E show the upper component 1110/1120 between central layers of thefilament based upper component 1210, this is not a requirement. Rather,the upper component 1110/1120 may be placed between any desired filamentlayers of upper component 1210 without departing from this invention(e.g., between layers closer to the upper interior and/or between layerscloser to the upper exterior).

The upper component 1110, 1120 may form any desired portion orproportion of the footwear upper structure without departing from thisinvention. As some more specific examples, the upper component 1110,1120 may provide or overlap with less than 50%, and in some examples,less than 40%, less than 30%, less than 20%, or even less than 10% of atotal surface area of the upper component 1210 (the term “total surfacearea” as used herein in this context means the complete area definedwithin the outermost perimeter of the upper component 1210, includingopen space defined between individual filaments of the upper component1210). The second (e.g., fabric) upper component 1110, 1120 may form anydesired portion of the overall upper construction, including one or moreof: an instep/tongue portion of the upper, a vamp portion of the upper,a lace-engaging portion of the upper, a foot-receiving opening of theupper, a collar of the upper, a rear heel engaging portion of the upper,etc.

FIGS. 7A-7C illustrate an example article of footwear 2000 including anupper 2002 having at least a portion formed as a multi-layered filamenttype upper blank 1000 of the types described above. As shown in thesefigures, the upper 2002 includes the combined upper component 1110,1120/upper component 1210, e.g., of the types described above inconjunction with FIGS. 6A-6E. The upper component 1110, 1120 may becombined with a filament based upper component (e.g., like upper blank1000) in any desired manner, including the various manners describedabove in conjunction with FIGS. 4A-6E. As shown in these figures, uppercomponent 1110, 1120 of this example is one or more fabric elements thatextend along a lace-engaging region and an instep region of the upper2002 (e.g., forming a “tongue” like element and/or vamp portion of theupper 2002), around the foot-insertion opening 2006 (e.g., to provide acomfort enhancing collar around the ankle), and down around a rear heelportion of the upper 2002 (e.g., to provide comfort at the heel).

Both the fabric upper component 1110, 1120 and the filament based uppercomponent 1210 of this illustrated example include openings and/or otherstructures for engaging a shoe lace 2008. Alternatively, if desired,only one of fabric upper component 1110, 1120 and the filament basedupper component 1210 may include lace engaging openings or structures.As another option or alternative, if desired, the fabric upper component1110, 1120 may include lace engaging openings or structures in one ormore areas of the upper 2002 and the filament based upper component 1210may include lace engaging openings or structures in one or more otherareas of the upper 2002. If desired, when the filament based uppercomponent 1210 engages the lace 2008, the lace 2008 may extend throughopenings provided in the filament based upper component 1210 betweenindividual filaments of a multi-layered upper structure.

The upper component 2002 may be engaged with a sole structure 2004 inany desired manner, including in conventional manners as are known andused in the footwear arts (e.g., adhesives, mechanical connectors, sewnseams, etc.). Any desired type of sole structure 2004 may be provided,including one or multi-part sole structures as are known and used in thefootwear arts. In some examples of this invention, the sole structure2004 will include a lightweight foam or fluid-filled bladder structure(optionally made from a hydrophobic, water-repelling, and/or non-waterabsorbing material(s)). The sole structure 2004 also may include trackspikes, cleats, and/or other traction enhancing elements.

Footwear uppers in accordance with examples of this invention, includingextruded filament based upper components of the types described above(including upper blank 1000, upper component 1210, and/or upper 2002),can provide many desirable properties, particularly for athleticfootwear constructions. The upper blank 1000, upper component 1210,and/or upper 2002 can be made very lightweight and/or breathable in viewof the large number of openings between the various filaments in thelayers, the thin structures of the filaments, and the relatively reducedvolume of heavier materials present. As another potential advantage, asnoted above, the filament(s) may be made from hydrophobic material(s)and/or material(s) that do not substantially absorb water. Thus, if theupper 2002 is exposed to wet conditions during use, the filament(s) mayshed/repel the water, maintaining a lightweight condition. The abilityto maintain a lightweight condition even when used in wet conditions canbe further enhanced in upper structures in which any fabric based uppercomponent(s) (e.g., component 1110, 1120) included in the upper 2002also is/are formed (at least in part) from hydrophobic material(s)and/or material(s) that do not substantially absorb water (such asthermoplastic polyurethane materials and/or other thermoplasticmaterials and/or other hydrophobic and/or water repelling materials thatmay be provided as the fusible component, e.g., in the manners describedin one or more of FIGS. 5D-5F) and/or if the sole structure 2004 isformed (at least in part) from hydrophobic material(s) and/ormaterial(s) that do not substantially absorb water (such asthermoplastic polyurethane materials and/or other thermoplasticmaterials and/or other hydrophobic and/or water repelling materials).When the upper component 1210 is formed at least in part as amulti-layered filament construction, many different colors and colorcombinations can be used to provide a wide range of aesthetic and designopportunities, including production of a moiré effect, e.g., as shown inFIGS. 1 and 3A-3P.

Also, the extruded filament type structures and production methods allowseamless transitions between upper structural features that providedifferent functions and/or characteristics (e.g., seamless transitionsbetween areas providing increased support and lock down with areasproviding improved flexibility; seamless changes in breathability indifferent areas; etc., by changing the filament sizes, spacings,materials, etc.). Moreover, a relatively uniform overall upper thicknesswith the multi-layered filament construction can provide varying stretchand/or breathability characteristics in different areas of the upperwith a seamless, one piece, unitary construction. As another potentialadvantage/feature, the upper blank 1000/upper component 1210 can beformed by the multi-layer extrusion process without producing tensilestresses to the individual filaments of the upper construction.

In the specific examples described above, the filament based uppercomponent forms an upper component (such as an upper blank) thatsubstantially covers or surrounds the wearer’s foot (from the rear heelarea, through the midfoot area, and to a forward toe area). Otheroptions are possible in which the filament based upper component (e.g.,having any desired number of extruded layers, including from 1 to 20layers, and in some examples, from 2 to 16 layers, 3 to 12 layers, 4-10layers, or even 8 layers) form one or more discrete portions of anoverall upper. FIGS. 8A and 8B illustrate an article of footwear 3000having such an upper 3002 engaged with a sole structure 3004. As shownin these figures, the upper 3002 of this example includes one or morefabric based upper components 3002 a and one or more extruded filamentbased upper components 3002 b (which may include one or more layers ofextruded filaments of the types described above). The extruded filamentbased upper components 3002 b of this example form a lateral side upperpanel (FIG. 8A) and a separate medial side upper panel (FIG. 8B). Theseextruded filament based upper components 3002 b may be engaged with theother upper component(s) 3002 a in any desired manner, including any ofthe manners described above in conjunction with FIGS. 4A to 6E(including via adhesives and/or in an adhesive free manner).

As further shown in FIGS. 8A and 8B, in this illustrated example, boththe fabric upper component 3002 a and the filament based upper component3002 b include openings and/or other structures for engaging a shoe lace3008. Alternatively, if desired, only one of fabric upper component 3002a and the filament based upper component 3002 b may include laceengaging openings or structures. As another option or alternative, ifdesired, the fabric upper component 3002 a may include lace engagingopenings or structures in one or more areas of the upper 3002 and thefilament based upper component 3002 b may include lace engaging openingsor structures in one or more other areas of the upper 3002. If desired,when the filament based upper component 3002 b engages the lace 3008,the lace 3008 may extend through openings provided in the filament basedupper component 3002 b between individual filaments of a multi-layeredupper structure.

The upper component 3002 a may have any desired structure and/or may bemade of any desired materials without departing from this invention,including conventional structures and/or materials as are known and usedin the footwear arts and/or structures as described above in conjunctionwith FIGS. 5A-7C (including hydrophobic, water-repelling, and/ornon-water absorbing material(s)). The sole structure 3004 may be anydesired type of sole structure, including one or multi-part solestructures as are known and used in the footwear arts. In some examplesof this invention, the sole structure 3004 will include a lightweightfoam or fluid-filled bladder structure (optionally made from ahydrophobic, water-repelling, and/or non-water absorbing material(s)).The sole structure 3004 also may include track spikes, cleats, and/orother traction enhancing elements.

Even with only a portion of the upper 3002 formed by extruded filamentbased upper components 3002 b, enhanced breathability and/or lightweightcharacteristics can be realized. The extruded filament based uppercomponents 3002 b can be placed at any locations where enhancedbreathability may be required or desired. As to weight reduction, in theexample structure of FIGS. 8A-8B, the use of the two extruded filamentbased upper components 3002 b reduces the overall weight of upper 3002by about 24 grams as compared to a similar upper made fully withcomponent 3002 a (i.e., with component 3002 a extending through themedial and lateral midfoot regions). In some examples of this invention,the filament based upper component(s) 3002 b may form from 15% to 100%of the overall upper surface area, and in some examples, from 25% to100%, 35% to 100%, 50% to 100%, or 60% to 100%, or even 75% to 100% ofthe overall upper surface area.

If desired, as generally shown in FIG. 9 , when one or more of the upperlayers (e.g., one or more of layers 300, 350, 400, 500, 600, 700, 800,and/or 900) are formed by filament extrusion/solid deposition modeling(e.g., forming upper blank 1000), a footwear strobel component (or sockliner) 1020 may be formed along with one or more of the filamentlayer(s) by the extrusion/solid deposition modeling technique(optionally, as part of a continuous path with one or more of thefilament layers). As shown in FIG. 9 , the strobel component 1020 may beintegrally formed with the upper component 1000, e.g., along one or moreedges of the upper component 1000 (e.g., at a lateral lower perimeteredge, a medial lower perimeter edge, a forefoot edge, one or more rearheel edges, etc.). The strobel component 1020 may be formed asfilaments, e.g., having any of the characteristics, features, and/oroptions for the filaments described above (e.g., with a grid or matrixstructure, in multiple layers, with intersecting/overlapping filamentpath segments, etc.). Once the overall upper/strobel combination 1040 isformed, the strobel 1020 can be folded along its integral edge with theupper component 1000 and attached at its free perimeter edge 1020P withthe bottom perimeter edge 1000P of the upper component 1000 (e.g., byadhesives, by fusing, etc.). The strobel component 1020 could be formedas two or more parts, e.g., at two or more separated locations along theupper perimeter 1000P.

III. Conclusion

The present invention is disclosed above and in the accompanyingdrawings with reference to a variety of embodiments and/or options. Thepurpose served by the disclosure, however, is to provide examples ofvarious features and concepts related to the invention, not to limit thescope of the invention. One skilled in the relevant art will recognizethat numerous variations and modifications may be made to the featuresof the invention described above without departing from the scope of thepresent invention, as defined by the appended claims.

For the avoidance of doubt, the present application includes at leastthe subject matter described in the following numbered Clauses:

Clause 1. An upper for an article of footwear, comprising:

-   a first upper component that includes a first layer including a    first material as a first filament including first plural,    non-intersecting, spaced apart path segments, wherein the first    filament has a width dimension of less than 1 mm wide; and-   a second upper component including a fabric element formed at least    in part of a fusible material; and-   wherein the fusible material of the second upper component is fused    to the first material of the first upper component.

Clause 2. The upper according to Clause 1, wherein the first uppercomponent further includes a second layer including a second material asa second filament including second plural, non-intersecting, spacedapart path segments, wherein the second filament has a width dimensionof less than 1 mm wide, and wherein the second layer is fused to thefirst layer at locations where the second layer contacts the firstlayer.

Clause 3. The upper according to Clause 2, wherein the second plural,non-intersecting, spaced apart path segments include at least 5 secondnon-intersecting path segments, wherein each non-intersecting pathsegment of the at least 5 second non-intersecting path segments isspaced apart from each directly adjacent second non-intersecting pathsegments by less than 5 mm over a length dimension of at least 25 mm.

Clause 4. The upper according to Clause 2, wherein the second plural,non-intersecting, spaced apart path segments include at least 5 secondnon-intersecting path segments, wherein each non-intersecting pathsegment of the at least 5 second non-intersecting path segments isspaced apart from each directly adjacent second non-intersecting pathsegments by less than 5 mm over a length dimension of at least 50 mm.

Clause 5. The upper according to any one of Clauses 2 to 4, wherein thesecond upper component has a first major surface and a second majorsurface opposite the first major surface, wherein the fusible materialat the first major surface of the second upper component is fused to thefirst material, and wherein the fusible material at the second majorsurface of the second upper component is fused to the second material.

Clause 6. The upper according to any one of Clauses 2 to 5, wherein aplurality of the second plural, non-intersecting, spaced apart pathsegments of the second filament extend parallel to and partially overlapwith a plurality of the first plural, non-intersecting, spaced apartpath segments of the first filament over a path segment length of atleast 25 mm.

Clause 7. The upper according to any one of Clauses 2 to 5, wherein aplurality of the second plural, non-intersecting, spaced apart pathsegments of the second filament extend parallel to and partially overlapwith a plurality of the first plural, non-intersecting, spaced apartpath segments of the first filament over a path segment length of atleast 50 mm.

Clause 8. The upper according to Clause 6 or 7, wherein 15% to 60% of awidth of one or more filaments of the plurality of the second plural,non-intersecting, spaced apart path segments of the second filamentoverlaps with a corresponding one or more filaments of the plurality ofthe first plural, non-intersecting, spaced apart path segments of thefirst filament over the path segment length.

Clause 9. The upper according to Clause 6 or 7, wherein 25% to 50% of awidth of one or more filaments of the plurality of the second plural,non-intersecting, spaced apart path segments of the second filamentoverlaps with a corresponding one or more filaments of the plurality ofthe first plural, non-intersecting, spaced apart path segments of thefirst filament over the path segment length.

Clause 10. The upper according to any one of Clauses 2 to 5, wherein aplurality of the second plural, non-intersecting, spaced apart pathsegments of the second filament intersect and form an angle with aplurality of the first plural, non-intersecting, spaced apart pathsegments of the first filament.

Clause 11. The upper according to Clause 10, wherein the angle is withina range of 65° to 90°.

Clause 12. The upper according to Clause 10 or 11, wherein the pluralityof the second plural, non-intersecting, spaced apart path segments ofthe second filament and the plurality of the first plural,non-intersecting, spaced apart path segments of the first filamentcooperate to form one or more diamond shapes.

Clause 13. The upper according to Clause 12, wherein the diamond shapesare located at least in a forefoot region of the upper.

Clause 14. The upper according to Clause 12 or 13, wherein a long axisof a plurality of the diamond shapes extend in substantially ananterior-posterior direction of the upper.

Clause 15. The upper according to any one of Clauses 2 to 14, whereinthe first filament has a first thickness at a first region of the upper,wherein the second filament has a second thickness at a second region ofthe upper, and wherein the first thickness differs from the secondthickness.

Clause 16. The upper according to any one of Clauses 2 to 15, whereinthe first filament has a first diameter at a first region of the upper,wherein the second filament has a second diameter at a second region ofthe upper, and wherein the first diameter differs from the seconddiameter.

Clause 17. The upper according to Clause 2, wherein portions of thefirst layer and the second layer form are oriented with respect to oneanother to form an intersecting grid of the first filament extending ina first direction and the second filament extending in a seconddirection.

Clause 18. The upper according to any one of Clauses 2 to 17, whereinthe first upper component further includes a third layer including athird material as a third filament including third plural,non-intersecting, spaced apart path segments, wherein the third filamenthas a width dimension of less than 1 mm wide, and wherein the thirdlayer is fused to either or both of the first layer and to the secondlayer at locations where the third layer contacts either or both of thefirst layer and the second layer, respectively.

Clause 19. The upper according to Clause 18, wherein the first uppercomponent further includes a fourth layer including a fourth material asa fourth filament including fourth plural, non-intersecting, spacedapart path segments, wherein the fourth filament has a width dimensionof less than 1 mm wide, and wherein the fourth layer is fused to any oneof or any combination of the first layer, the second layer, and thethird layer at locations where the fourth layer contacts to any one ofor any combination of the first layer, the second layer, and the thirdlayer, respectively.

Clause 20. The upper according to Clause 19, wherein the first uppercomponent further includes a fifth layer including a fifth material as afifth filament including fifth plural, non-intersecting, spaced apartpath segments, wherein the fifth filament has a width dimension of lessthan 1 mm wide, and wherein the fifth layer is fused to any one of orany combination of the first layer, the second layer, the third layer,and the fourth layer at locations where the fifth layer contacts any oneof or any combination of the first layer, the second layer, the thirdlayer, and the fourth layer, respectively.

Clause 21. The upper according to Clause 20, wherein the first uppercomponent further includes a sixth layer including a sixth material as asixth filament including sixth plural, non-intersecting, spaced apartpath segments, wherein the sixth filament has a width dimension of lessthan 1 mm wide, and wherein the sixth layer is fused to any one of orany combination of the first layer, the second layer, the third layer,the fourth layer, and the fifth layer at locations where the sixth layercontacts any one of or any combination of the first layer, the secondlayer, the third layer, the fourth layer, and the fifth layer,respectively.

Clause 22. The upper according to Clause 21, wherein the first uppercomponent further includes a seventh layer including a seventh materialas a seventh filament including seventh plural, non-intersecting, spacedapart path segments, wherein the seventh filament has a width dimensionof less than 1 mm wide, and wherein the seventh layer is fused to anyone of or any combination of the first layer, the second layer, thethird layer, the fourth layer, the fifth layer, and the sixth layer atlocations where the seventh layer contacts any one of or any combinationof the first layer, the second layer, the third layer, the fourth layer,the fifth layer, and the sixth layer, respectively.

Clause 23. The upper according to Clause 22, wherein the first uppercomponent further includes an eighth layer including an eighth materialas an eighth filament including eighth plural, non-intersecting, spacedapart path segments, wherein the eighth filament has a width dimensionof less than 1 mm wide, and wherein the eighth layer is fused to any oneof or any combination of the first layer, the second layer, the thirdlayer, the fourth layer, the fifth layer, the sixth layer, and theseventh layer at locations where the eighth layer contacts any one of orany combination of the first layer, the second layer, the third layer,the fourth layer, the fifth layer, the sixth layer, and the seventhlayer, respectively.

Clause 24. The upper according to any one of Clauses 1 to 23, whereinthe first filament of the first layer defines a perimeter, and whereinfilament segments of the first filament extend between portions of theperimeter.

Clause 25. The upper according to any one of Clauses 1 to 24, whereinthe first plural, non-intersecting, spaced apart path segments extend ina serpentine configuration including at least two peaks and at least twovalleys.

Clause 26. The upper according to any one of Clauses 1 to 24, whereinthe first plural, non-intersecting, spaced apart path segments extend ina substantially anterior-posterior direction of the upper and include aserpentine configuration having at least two peaks and at least twovalleys.

Clause 27. The upper according to Clause 25 or 26, wherein theserpentine configuration is formed at least at a medial midfoot portionof the upper component.

Clause 28. The upper according to Clause 25 or 26, wherein theserpentine configuration is formed at least at a lateral midfoot portionof the upper component.

Clause 29. The upper according to any one of Clauses 1 to 28, whereinthe first filament has a first thickness at a first region of the upper,wherein the first filament has a second thickness at a second region ofthe upper, and wherein the first thickness differs from the secondthickness.

Clause 30. The upper according to any one of Clauses 1 to 28, whereinthe first filament has a first diameter at a first region of the upper,wherein the first filament has a second diameter at a second region ofthe upper, and wherein the first diameter differs from the seconddiameter.

Clause 31. The upper according to any one of Clauses 1 to 30, whereinthe first layer forms a perimeter of the upper.

Clause 32. The upper according to any one of Clauses 1 to 31, whereinthe filament in each layer of the first upper component is made from thesame material.

Clause 33. The upper according to any one of Clauses 1 to 32, whereinthe filament in each layer of the first upper component comprises athermoplastic polyurethane material or other thermoplastic material.

Clause 34. The upper according to any one of Clauses 1 to 33, whereinthe filament in each layer of the first upper component comprises amaterial that does not substantially absorb water.

Clause 35. The upper according to any one of Clauses 1 to 34, whereinthe filament in each layer of the first upper component comprises ahydrophobic material.

Clause 36. The upper according to any one of Clauses 1 to 35, wherein atleast a portion of the first upper component exhibits a moiré effect.

Clause 37. The upper according to any one of Clauses 1 to 36, whereinthe second upper component has a first major surface and a second majorsurface opposite the first major surface, and wherein the first uppercomponent is engaged at least with the first major surface of the secondupper component.

Clause 38. The upper according to any one of Clauses 1 to 37, whereinthe first plural, non-intersecting, spaced apart path segments includeat least 5 first non-intersecting path segments, wherein eachnon-intersecting path segment of the at least 5 first non-intersectingpath segments is spaced apart from each directly adjacent firstnon-intersecting path segments by less than 5 mm over a length dimensionof at least 25 mm.

Clause 39. The upper according to any one of Clauses 1 to 37, whereinthe first plural, non-intersecting, spaced apart path segments includeat least 5 first non-intersecting path segments, wherein eachnon-intersecting path segment of the at least 5 first non-intersectingpath segments is spaced apart from each directly adjacent firstnon-intersecting path segments by less than 5 mm over a length dimensionof at least 50 mm.

Clause 40. The upper according to any one of Clauses 1 to 39, whereinthe second upper component forms an instep portion or a vamp portion ofthe upper.

Clause 41. The upper according to any one of Clauses 1 to 40, whereinthe second upper component defines a foot-receiving opening or a collarof the upper.

Clause 42. The upper according to any one of Clauses 1 to 41, whereinthe second upper component forms a rear heel engaging portion of theupper.

Clause 43. The upper according to any one of Clauses 40 to 42, whereinthe first upper component is engaged with an exterior surface of thesecond upper component.

Clause 44. The upper according to any one of Clauses 1 to 43, whereinthe second upper component overlaps with less than 30% of a totalsurface area of the first upper component.

Clause 45. The upper according to any one of Clauses 1 to 44, whereinthe fabric element of the second upper component includes at least oneyarn formed from the fusible material.

Clause 46. The upper according to any one of Clauses 1 to 44, whereinthe fabric element of the second upper component includes a first yarnformed from the fusible material intertwined with a second yarn formedfrom a non-fusible material.

Clause 47. The upper according to any one of Clauses 1 to 44, whereinthe fabric element of the second upper component includes a first yarnformed from a non-fusible material at least partially coated with thefusible material.

Clause 48. The upper according to Clause 46 or 47, wherein thenon-fusible material comprises a polyester material.

Clause 49. The upper according to any one of Clauses 1 to 48, whereinthe fusible material comprises a thermoplastic polyurethane material orother thermoplastic material.

Clause 50. An article of footwear, comprising:

-   an upper according to any one of Clauses 1 to 49; and-   a sole structure engaged with the upper.

Clause 51. A method of forming an upper for an article of footwear,comprising:

-   extruding a first material to form a first layer comprising a first    extruded filament including first plural, non-intersecting, spaced    apart path segments, wherein the first extruded filament has a width    dimension of less than 1 mm wide, and wherein the first layer forms    at least a portion of a first upper component; and-   fusing a second upper component to the first upper component,    wherein the second upper component includes a fabric element formed    at least in part of a fusible material, wherein fusible material of    the second upper component is fused to the first material of the    first upper component.

Clause 52. The method according to Clause 51, further comprising:extruding a second material to form a second layer comprising a secondextruded filament including second plural, non-intersecting, spacedapart path segments, wherein the second extruded filament has a widthdimension of less than 1 mm wide, wherein the step of extruding thesecond material includes fusing the second layer to the first layer atlocations where the second layer contacts the first layer, and whereinthe second layer forms a portion of the first upper component.

Clause 53. The method according to Clause 52, wherein a plurality of thesecond plural, non-intersecting, spaced apart path segments of thesecond filament are extruded to extend parallel to and partially overlapwith a plurality of the first plural, non-intersecting, spaced apartpath segments of the first filament over a path segment length of atleast 25 mm.

Clause 54. The method according to Clause 52, wherein a plurality of thesecond plural, non-intersecting, spaced apart path segments of thesecond filament are extruded to extend parallel to and partially overlapwith a plurality of the first plural, non-intersecting, spaced apartpath segments of the first filament over a path segment length of atleast 50 mm.

Clause 55. The method according to Clause 53 or 54, wherein 15% to 60%of a width of one or more filaments of the plurality of the secondplural, non-intersecting, spaced apart path segments of the secondfilament are extruded to overlap with a corresponding one or morefilaments of the plurality of the first plural, non-intersecting, spacedapart path segments of the first filament over the path segment length.

Clause 56. The method according to Clause 53 or 54, wherein 25% to 50%of a width of one or more filaments of the plurality of the secondplural, non-intersecting, spaced apart path segments of the secondfilament are extruded to overlap with a corresponding one or morefilaments of the plurality of the first plural, non-intersecting, spacedapart path segments of the first filament over the path segment length.

Clause 57. The method according to Clause 52, wherein a plurality of thesecond plural, non-intersecting, spaced apart path segments of thesecond filament are extruded to intersect and form an angle with aplurality of the first plural, non-intersecting, spaced apart pathsegments of the first filament.

Clause 58. The method according to Clause 57, wherein the angle iswithin a range of 65° to 90°.

Clause 59. The method according to Clause 57 or 58, wherein theplurality of the second plural, non-intersecting, spaced apart pathsegments of the second filament and the plurality of the first plural,non-intersecting, spaced apart path segments of the first filament areextruded to form diamond shapes.

Clause 60. The method according to Clause 59, wherein at least a portionof the diamond shapes located at least in a forefoot region of theupper.

Clause 61. The method according to Clause 59 or 60, wherein a long axisof at least a portion of the diamond shapes extend in substantially ananterior-posterior direction of the upper.

Clause 62. The method according to any one of Clauses 52 to 61, whereinthe first filament is extruded to have a first thickness at a firstregion of the upper, wherein the second filament is extruded to have asecond thickness at a second region of the upper, and wherein the firstthickness differs from the second thickness.

Clause 63. The method according to any one of Clauses 52 to 62, whereinthe first filament is extruded to have a first diameter at a firstregion of the upper, wherein the second filament is extruded to have asecond diameter at a second region of the upper, and wherein the firstdiameter differs from the second diameter.

Clause 64. The method according to Clause 52, wherein portions of thefirst layer and the second layer form are extruded to be oriented withrespect to one another to form an intersecting grid of the firstfilament extending in a first direction and the second filamentextending in a second direction.

Clause 65. The method according to any one of Clauses 52 to 64, furthercomprising: extruding a third material to form a third layer comprisinga third extruded filament including third plural, non-intersecting,spaced apart path segments, wherein the third extruded filament has awidth dimension of less than 1 mm wide, wherein the step of extrudingthe third material includes fusing the third layer to either or both ofthe first layer and the second layer at locations where the third layercontacts either or both of the first layer and the second layer,respectively, and wherein the third layer forms a portion of the firstupper component.

Clause 66. The method according to Clause 65, further comprising:extruding a fourth material to form a fourth layer comprising a fourthextruded filament including fourth plural, non-intersecting, spacedapart path segments, wherein the fourth extruded filament has a widthdimension of less than 1 mm wide, wherein the step of extruding thefourth material includes fusing the fourth layer to any one of or anycombination of the first layer, the second layer, and the third layer atlocations where the fourth layer contacts any one of or any combinationof the first layer, the second layer, and the third layer, respectively,and wherein the fourth layer forms a portion of the first uppercomponent.

Clause 67. The method according to Clause 66, further comprising:extruding a fifth material to form a fifth layer comprising a fifthextruded filament including fifth plural, non-intersecting, spaced apartpath segments, wherein the fifth extruded filament has a width dimensionof less than 1 mm wide, wherein the step of extruding the fifth materialincludes fusing the fifth layer to any one of or any combination of thefirst layer, the second layer, the third layer, and the fourth layer atlocations where the fifth layer contacts any one of or any combinationof the first layer, the second layer, the third layer, and the fourthlayer, respectively, and wherein the fifth layer forms a portion of thefirst upper component.

Clause 68. The method according to Clause 67, further comprising:extruding a sixth material to form a sixth layer comprising a sixthextruded filament including sixth plural, non-intersecting, spaced apartpath segments, wherein the sixth extruded filament has a width dimensionof less than 1 mm wide, wherein the step of extruding the sixth materialincludes fusing the sixth layer to any one of or any combination of thefirst layer, the second layer, the third layer, the fourth layer, andthe fifth layer at locations where the sixth layer contacts any one ofor any combination of the first layer, the second layer, the thirdlayer, the fourth layer, and the fifth layer, respectively, and whereinthe sixth layer forms a portion of the first upper component.

Clause 69. The method according to Clause 68, further comprising:extruding a seventh material to form a seventh layer comprising aseventh extruded filament including seventh plural, non-intersecting,spaced apart path segments, wherein the seventh extruded filament has awidth dimension of less than 1 mm wide, wherein the step of extrudingthe seventh material includes fusing the seventh layer to any one of orany combination of the first layer, the second layer, the third layer,the fourth layer, the fifth layer, and the sixth layer at locationswhere the seventh layer contacts any one of or any combination of thefirst layer, the second layer, the third layer, the fourth layer, thefifth layer, and the sixth layer, respectively, and wherein the seventhlayer forms a portion of the first upper component.

Clause 70. The method according to Clause 69, further comprising:extruding an eighth material to form an eighth layer comprising aneighth extruded filament including eighth plural, non-intersecting,spaced apart path segments, wherein the eighth extruded filament has awidth dimension of less than 1 mm wide, wherein the step of extrudingthe eighth material includes fusing the eighth layer to any one of orany combination of the first layer, the second layer, the third layer,the fourth layer, the fifth layer, the sixth layer, and the seventhlayer at locations where the eighth layer contacts any one of or anycombination of the first layer, the second layer, the third layer, thefourth layer, the fifth layer, the sixth layer, and the seventh layer,respectively, and wherein the eighth layer forms a portion of the firstupper component.

Clause 71. The method according to any one of Clauses 51 to 70, whereinthe step of fusing the second upper component to the first uppercomponent includes fusing an interior surface of first upper componentwith an exterior surface of the second upper component.

Clause 72. A method of forming an upper for an article of footwear,comprising:

-   extruding a first material to form a first layer comprising a first    extruded filament including first plural, non-intersecting, spaced    apart path segments, wherein the first extruded filament has a width    dimension of less than 1 mm wide, and wherein the first layer forms    a portion of a first upper component;-   covering a portion of the first layer with a release liner;-   extruding a second material to form a second layer comprising a    second extruded filament including second plural, non-intersecting,    spaced apart path segments, wherein the second extruded filament has    a width dimension of less than 1 mm wide, wherein the step of    extruding the second material includes: (a) applying a first portion    of the second layer to the release liner such that the release liner    extends between a first portion of the first layer and the first    portion of the second layer and (b) fusing a second portion of the    second layer to a second portion of the first layer at locations    where the second layer contacts the first layer, and wherein the    second layer forms a portion of the first upper component;-   removing the release liner from between the first portion of the    first layer and the first portion of the second layer;-   placing a portion of a second upper component between the first    portion of the first layer and the first portion of the second    layer, wherein the portion of the second upper component includes a    fabric element formed at least in part of a fusible material; and-   fusing the second upper component to the first upper component,    wherein fusible material of the second upper component is fused to    the first material of the first upper component and to the second    material of the first upper component.

Clause 73. The method according to Clause 72, wherein the second uppercomponent includes a first major surface and a second major surfaceopposite the first major surface, wherein in the placing step, theportion of the second upper component is placed between the firstportion of the first layer and the first portion of the second layersuch that: (a) the first major surface directly contacts the first layerand does not directly contact the second layer and (b) the second majorsurface directly contacts the second layer and does not directly contactthe first layer.

Clause 74. The method according to Clause 72 or 73, further comprising:

-   fusing the first material to the fusible material of the second    upper component; and-   fusing the second material to the fusible material of the second    upper component.

Clause 75. The method according to any one of Clauses 72 to 74, whereinthe step of extruding the first material includes extruding the firstmaterial onto a pre-existing layer including filament material.

Clause 76. The method according to any one of Clauses 72 to 75, whereinprior to fusing the second upper component to the first upper component,the method further comprises: extruding a third material to form a thirdlayer comprising a third extruded filament to at least partially overlapthe first layer and the second layer, wherein the third extrudedfilament has a width dimension of less than 1 mm wide, wherein the stepof extruding the third material includes: (a) applying a first portionof the third layer to the release liner such that the release linerextends between the first portion of the first layer and the firstportion of the third layer and (b) fusing a second portion of the thirdlayer to either or both of portions of the first layer and the secondlayer at locations where the third layer contacts either or both of thefirst layer and the second layer, respectively, and wherein the thirdlayer forms a portion of the first upper component.

Clause 77. The method according to any one of Clauses 51 to 76, whereinthe first upper component is completely formed before the second uppercomponent is fused to the first upper component.

Clause 78. The method according to any one of Clauses 51 to 77, whereinthe first filament of the first layer is extruded to define a perimeterand to produce filament segments of the first filament extending betweenportions of the perimeter.

Clause 79. The method according to any one of Clauses 51 to 78, whereinthe first plural, non-intersecting, spaced apart path segments areextruded to extend in a serpentine configuration including at least twopeaks and at least two valleys.

Clause 80. The method according to any one of Clauses 51 to 78, whereinthe first plural, non-intersecting, spaced apart path segments areextruded to extend in a substantially anterior-posterior direction ofthe upper and include a serpentine configuration having at least twopeaks and at least two valleys.

Clause 81. The method according to Clause 79 or 80, wherein the firstplural, non-intersecting, spaced apart path segments are extruded toform the serpentine configuration at least at a medial midfoot portionof the upper component.

Clause 82. The method according to Clause 79 or 80, wherein the firstplural, non-intersecting, spaced apart path segments are extruded toform the serpentine configuration at least at a lateral midfoot portionof the upper component.

Clause 83. The method according to any one of Clauses 51 to 82, whereinthe first filament is extruded to have a first thickness at a firstregion of the upper, wherein the first filament is extruded to have asecond thickness at a second region of the upper, and wherein the firstthickness differs from the second thickness.

Clause 84. The method according to any one of Clauses 51 to 82, whereinthe first filament is extruded to have a first diameter at a firstregion of the upper, wherein the first filament is extruded to have asecond diameter at a second region of the upper, and wherein the firstdiameter differs from the second diameter.

Clause 85. The method according to any one of Clauses 51 to 84, whereinthe first filament is extruded to form a perimeter of the upper.

Clause 86. The method according to any one of Clauses 51 to 85, whereinthe extruded filament in each layer of the first upper component is madefrom the same material.

Clause 87. The method according to any one of Clauses 51 to 86, whereinthe extruded filament in each layer of the first upper componentcomprises a thermoplastic polyurethane material or other thermoplasticmaterial.

Clause 88. The method according to any one of Clauses 51 to 87, whereinthe extruded filament in each layer of the first upper componentcomprises a material that does not substantially absorb water.

Clause 89. The method according to any one of Clauses 51 to 88, whereinthe extruded filament in each layer of the first upper componentcomprises a hydrophobic material.

Clause 90. The method according to any one of Clauses 51 to 89, whereinat least a portion of the first upper component exhibits a moiré effect.

Clause 91. The method according to any one of Clauses 51 to 90, whereinthe second upper component forms an instep portion or a vamp portion ofthe upper.

Clause 92. The method according to any one of Clauses 51 to 91, whereinthe second upper component defines a foot-receiving opening or a collarof the upper.

Clause 93. The method according to any one of Clauses 51 to 92, whereinthe second upper component forms a rear heel engaging portion of theupper.

Clause 94. The method according to any one of Clauses 51 to 93, whereinthe second upper component overlaps with less than 30% of a totalsurface area of the first upper component.

Clause 95. The method according to any one of Clauses 51 to 94, whereinthe fabric element of the second upper component includes at least oneyarn formed from the fusible material.

Clause 96. The method according to any one of Clauses 51 to 94, whereinthe fabric element of the second upper component includes a first yarnformed from the fusible material intertwined with a second yarn formedfrom a non-fusible material.

Clause 97. The method according to any one of Clauses 51 to 94, whereinthe fabric element of the second upper component includes a first yarnformed from a non-fusible material at least partially coated with thefusible material.

Clause 98. The method according to Clause 96 or 97, wherein thenon-fusible material comprises a polyester material.

Clause 99. The method according to any one of Clauses 51 to 98, whereinthe fusible material comprises a thermoplastic polyurethane material orother thermoplastic material.

Clause 100. A method of forming an upper for an article of footwear,comprising:

-   extruding a first material to form a first layer comprising a first    extruded filament including first plural, non-intersecting, spaced    apart path segments, wherein the first extruded filament has a width    dimension of less than 1 mm wide, and wherein the first layer forms    at least a portion of a first upper component;\-   covering a portion of the first layer with a release liner;-   extruding a second material to form a second layer comprising a    second extruded filament including second plural, non-intersecting,    spaced apart path segments, wherein the second extruded filament has    a width dimension of less than 1 mm wide, wherein the step of    extruding the second material includes: (a) applying a first portion    of the second layer to the release liner such that the release liner    extends between a first portion of the first layer and the first    portion of the second layer and (b) fusing a second portion of the    second layer to a second portion of the first layer at locations    where the second layer contacts the first layer, and wherein the    second layer forms a portion of the first upper component; and-   removing the release liner from between the first portion of the    first layer and the first portion of the second layer.

Clause 101. The method according to Clause 100, wherein the step ofextruding the first material includes extruding the first material ontoa pre-existing layer including filament material.

Clause 102. The method according to Clause 100 or 101, wherein the firstfilament of the first layer is extruded to define a perimeter and toproduce filament segments of the first filament extending betweenportions of the perimeter.

Clause 103. The method according to any one of Clauses 100 to 102,wherein the first plural, non-intersecting, spaced apart path segmentsare extruded to extend in a serpentine configuration including at leasttwo peaks and at least two valleys.

Clause 104. The method according to any one of Clauses 100 to 102,wherein the first plural, non-intersecting, spaced apart path segmentsare extruded to extend in a substantially anterior-posterior directionof the upper and include a serpentine configuration having at least twopeaks and at least two valleys.

Clause 105. The method according to Clause 103 or 104, wherein the firstplural, non-intersecting, spaced apart path segments are extruded toform the serpentine configuration at least at a medial midfoot portionof the upper component.

Clause 106. The method according to Clause 103 or 104, wherein the firstplural, non-intersecting, spaced apart path segments are extruded toform the serpentine configuration at least at a lateral midfoot portionof the upper component.

Clause 107. The method according to any one of Clauses 100 to 106,wherein the first filament is extruded to have a first thickness at afirst region of the upper, wherein the first filament is extruded tohave a second thickness at a second region of the upper, and wherein thefirst thickness differs from the second thickness.

Clause 108. The method according to any one of Clauses 100 to 106,wherein the first filament is extruded to have a first diameter at afirst region of the upper, wherein the first filament is extruded tohave a second diameter at a second region of the upper, and wherein thefirst diameter differs from the second diameter.

Clause 109. The method according to any one of Clauses 100 to 108,wherein the first filament is extruded to form a perimeter of the upper.

Clause 110. The method according to any one of Clauses 100 to 109,wherein the first extruded filament and the second extruded filament aremade from the same material.

Clause 111. The method according to any one of Clauses 100 to 109,wherein the first extruded filament and the second extruded filament aremade from different materials.

Clause 112. The method according to any one of Clauses 100 to 111,wherein the first extruded filament and the second extruded filamenteach comprises a thermoplastic polyurethane material or otherthermoplastic material.

Clause 113. The method according to any one of Clauses 100 to 112,wherein the first extruded filament and the second extruded filamenteach comprises a material that does not substantially absorb water.

Clause 114. The method according to any one of Clauses 100 to 113,wherein the first extruded filament and the second extruded filamenteach comprises a hydrophobic material.

Clause 115. The method according to any one of Clauses 100 to 114,wherein at least a portion of the first upper component exhibits a moiréeffect.

Clause 116. The method according to any one of Clauses 100 to 115,wherein the portion of the first layer covered with the release linerstep extends inwardly from a peripheral edge of the first layer.

Clause 117. A method of making an article of footwear, comprising:

-   forming an upper according to any one of Clauses 51 to 116; and-   engaging the upper with a sole structure.

Clause 118. An upper formed by the method of any one of Clauses 51 to116.

What is claimed is:
 1. An upper for an article of footwear, comprising:a first upper component that includes: a first filament layer formedfrom a first material as a first continuous path of a first extrudedfilament, the first filament layer including first plural,non-intersecting, spaced apart path segments extending in asubstantially medio-lateral direction of the upper, wherein the firstextruded filament has a width dimension of less than 3 mm wide, andwherein the first continuous path of the first extruded filament formingthe first filament layer extends continuously to form (i) a lateral rearheel portion of the first filament layer, (ii) a lateral midfoot portionof the first filament layer, (iii) a forefoot portion of the firstfilament layer, (iv) a medial midfoot portion of the first filamentlayer, and (v) a medial rear heel portion of the first filament layer,and a second filament layer formed from a second material as a secondcontinuous path of a second extruded filament, the second filament layerincluding second plural, non-intersecting, spaced apart path segmentsextending in a substantially anterior-posterior direction of the upper,wherein the second extruded filament has a width dimension of less than3 mm wide, wherein the second continuous path of the second extrudedfilament forming the second filament layer extends continuously to form(i) a lateral rear heel portion of the second filament layer, (ii) alateral midfoot portion of the second filament layer, (iii) a forefootportion of the second filament layer, (iv) a medial midfoot portion ofthe second filament layer, and (v) a medial rear heel portion of thesecond filament layer; and a second upper component including a fabricelement formed at least in part of a fusible material, wherein thefusible material of the second upper component is fused to the firstmaterial of the first upper component.
 2. The upper according to claim1, wherein the second plural, non-intersecting, spaced apart pathsegments include at least 5 second non-intersecting path segments,wherein each non-intersecting path segment of the at least 5 secondnon-intersecting path segments is spaced apart from each directlyadjacent second non-intersecting path segments.
 3. The upper accordingto claim 1, wherein the second upper component has a first major surfaceand a second major surface opposite the first major surface, wherein thefusible material located at the first major surface of the second uppercomponent is fused to the first material forming the first filamentlayer, and wherein the fusible material located at the second majorsurface of the second upper component is fused to the second materialforming the second filament layer.
 4. The upper according to claim 3,wherein a plurality of the second plural, non-intersecting, spaced apartpath segments of the second filament layer extend parallel to andpartially overlap with a plurality of the first plural,non-intersecting, spaced apart path segments of the first filamentlayer.
 5. The upper according to claim 1, wherein a plurality of thesecond plural, non-intersecting, spaced apart path segments of thesecond filament layer intersect and form an angle with a plurality ofthe first plural, non-intersecting, spaced apart path segments of thefirst filament layer.
 6. The upper according to claim 5, wherein theplurality of the second plural, non-intersecting, spaced apart pathsegments of the second filament layer and the plurality of the firstplural, non-intersecting, spaced apart path segments of the firstfilament layer cooperate to form one or more diamond shapes, and whereina long axis of a plurality of the diamond shapes extend in thesubstantially anterior-posterior direction of the upper.
 7. The upperaccording to claim 1, wherein the first upper component further includesa third filament layer formed from a third material as a thirdcontinuous path of a third extruded filament, the third filament layerincluding third plural, non-intersecting, spaced apart path segments,wherein the third extruded filament has a width dimension of less than 3mm wide, wherein the third continuous path of the third extrudedfilament forming the third filament layer extends continuously to form(i) a lateral rear heel portion of the third filament layer, (ii) alateral midfoot portion of the third filament layer, (iii) a forefootportion of the third filament layer, (iv) a medial midfoot portion ofthe third filament layer, and (v) a medial rear heel portion of thethird filament layer, and wherein the third filament layer is fused toeither or both of the first filament layer and the second filament layerat locations where the third filament layer contacts either or both ofthe first filament layer and the second filament layer.
 8. The upperaccording to claim 1, wherein the second extruded filament partiallyoverlays the first extruded filament, and wherein the second filamentlayer is fused to the first filament layer at locations where the secondfilament layer contacts the first filament layer.
 9. The upper accordingto claim 1, wherein the second plural, non-intersecting, spaced apartpath segments extend in a serpentine configuration including at leasttwo peaks and at least two valleys.
 10. The upper according to claim 9,wherein the serpentine configuration is formed at least at a medialmidfoot portion of the first upper component, or wherein the serpentineconfiguration is formed at least at a lateral midfoot portion of thefirst upper component.
 11. The upper according to claim 1, wherein atleast a portion of the first upper component exhibits a moiré effect.12. An upper for an article of footwear, comprising: a first uppercomponent that includes a first filament layer and a second filamentlayer, wherein: the first filament layer is formed from a first materialas a first continuous path of a first extruded filament including firstplural, non-intersecting, spaced apart path segments extending in asubstantially medio-lateral direction of the upper, and wherein thefirst continuous path of the first extruded filament forming the firstfilament layer extends continuously from a rear heal portion to aforefoot portion, and the second filament layer is formed from a secondmaterial as a second continuous path of a second extruded filamentincluding second plural, non-intersecting, spaced apart path segmentsextending in a substantially anterior-posterior direction of the upper,wherein the second continuous path of the second extruded filamentforming the second filament layer extends continuously from the rearheel portion to the forefoot portion wherein the second extrudedfilament partially overlays the first extruded filament, and wherein thesecond filament layer is fused to the first filament layer at locationswhere the second filament layer contacts the first filament layer; and asecond upper component including a fabric element formed at least inpart of a fusible material, wherein the fusible material of the secondupper component is fused to the first material of the first uppercomponent.
 13. The upper according to claim 12, wherein the firstextruded filament has a width dimension of less than 3 mm wide, and thesecond extruded filament has a width dimension of less than 2 mm wide.14. The upper according to claim 12, wherein: the first continuous pathof the first extruded filament forming the first filament layer extendscontinuously to form (i) a lateral rear heel portion of the firstfilament layer, (ii) a lateral midfoot portion of the first filamentlayer, (iii) a forefoot portion of the first filament layer, (iv) amedial midfoot portion of the first filament layer, and (v) a medialrear heel portion of the first filament layer, and the second continuouspath of the second extruded filament forming the second filament layerextends continuously to form (i) a lateral rear heel portion of thesecond filament layer, (ii) a lateral midfoot portion of the secondfilament layer, (iii) a forefoot portion of the second filament layer,(iv) a medial midfoot portion of the second filament layer, and (v) amedial rear heel portion of the second filament layer.
 15. The upperaccording to claim 12 wherein the first plural, non-intersecting, spacedapart path segments include at least 5 first non-intersecting pathsegments, and wherein each non-intersecting path segment of the at least5 first non-intersecting path segments is spaced apart from eachdirectly adjacent first non-intersecting path segments.
 16. The upperaccording to claim 12, wherein: (a) the second upper component forms aninstep portion or a vamp portion of the upper; (b) the second uppercomponent defines a foot-receiving opening or a collar of the upper; (c)the second upper component forms a rear heel engaging portion of theupper; (d) the first upper component is engaged with an exterior surfaceof the second upper component; and/or (e) the second upper componentoverlaps with less than 30% of a total surface area of the first uppercomponent.
 17. The upper according to claim 1, wherein: the fabricelement of the second upper component includes a first yarn formed fromthe fusible material intertwined with a second yarn formed from anon-fusible material; or the fabric element of the second uppercomponent includes a first yarn formed from a non-fusible material atleast partially coated with the fusible material.
 18. The upperaccording to claim 1, wherein the fusible material of the second uppercomponent comprises a thermoplastic polyurethane located on both aninner side and an outer side of the second upper component.
 19. An upperfor an article of footwear, comprising: a first upper component; and asecond upper component including a fabric element formed at least inpart of a fusible material, wherein the fusible material of the secondupper component is fused to the first upper component, wherein the firstupper component includes a first filament layer and a second filamentlayer, wherein the first filament layer is formed from a first materialas a first continuous path of a first extruded filament including firstplural, non-intersecting, spaced apart path segments extending in asubstantially medio-lateral direction of the upper, and wherein thefirst continuous path of the first extruded filament forming the firstfilament layer extends continuously to form a plurality of portionsextending from a rear heel portion to a forefoot portion, and whereinthe second filament layer is formed from a second material as a secondcontinuous path of a second extruded filament including second plural,non-intersecting, spaced apart path segments extending in asubstantially anterior-posterior direction of the upper, wherein thesecond continuous path of the second extruded filament forming thesecond filament layer extends continuously to form a plurality ofportions extending from the rear heel portion to the forefoot portion.20. The upper according to claim 19, wherein the second upper componenthas a first major surface and a second major surface opposite the firstmajor surface, wherein the fusible material located at the first majorsurface of the second upper component is fused to the first materialforming the first filament layer, wherein the fusible material locatedat the second major surface of the second upper component is fused tothe second material forming the second filament layer, and wherein aplurality of the second plural, non-intersecting, spaced apart pathsegments of the second filament layer extend parallel to and partiallyoverlap with a plurality of the first plural, non-intersecting, spacedapart path segments of the first filament layer.